OIL-FREE SCROLL COMPRESSORS - Air Compressors Direct€¦ · QOF 20, QOF 22 and QOF 30 are...

OIL-FREESCROLLCOMPRESSORS

QOF20,QOF22,QOF30

InstructionManual

Thismanualcontainsimportantsafetyinformationandshouldbemadeavailabletoall personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this equipment.

ManualNo.2930 7140 30

November2014Edition

Table of Contents

Quincy Compressor

Section I - General InformationSafetyAlertSymbols ...........................................................................................................1SafetyPrecautions ...............................................................................................................2SparePartsOrderingInformation .......................................................................................3Serial/ModelIdentificationPlate .........................................................................................3Warranty ..............................................................................................................................4

Section II - DescriptionGeneraldescription .............................................................................................................5Flowdiagram .......................................................................................................................8Regulating system .............................................................................................................10Electricalsystem ................................................................................................................10Electricdiagram .................................................................................................................11Temperatureprotection .....................................................................................................11Airdryer .............................................................................................................................12

Section III - ControllerGeneral ..............................................................................................................................14Control panel .....................................................................................................................16Iconsused .........................................................................................................................17Main screen .......................................................................................................................22Calling up menus ...............................................................................................................26Shutdown warning .............................................................................................................27Shutdown ..........................................................................................................................31Inputsmenu .......................................................................................................................32Outputs menu ...................................................................................................................35Counters ............................................................................................................................36Control mode selection .....................................................................................................37Service menu .....................................................................................................................39Setpoint menu ...................................................................................................................43Eventhistorymenu ............................................................................................................45Generalsettingsmenu ......................................................................................................46Infomenu ..........................................................................................................................48Weektimermenu ..............................................................................................................49Testmenu ..........................................................................................................................59Userpasswordmenu .........................................................................................................60Webserver ........................................................................................................................61Programmablesettings .....................................................................................................69

Section IV - Installation guidelines Dimensiondrawing ...........................................................................................................72Installationproposal ..........................................................................................................72Electricalconnections ........................................................................................................75Pictographs ........................................................................................................................76

Section V - Operating instructionsInitialstart-up .....................................................................................................................77Starting ..............................................................................................................................78Duringoperation ...............................................................................................................78

Table of Contents

Quincy Compressor

Stopping ............................................................................................................................79Takingoutofoperation .....................................................................................................79

Section VI - MaintenancePreventivemaintenanceschedule .....................................................................................80Servicekits .........................................................................................................................82Disposalofusedmaterial ..................................................................................................82

Section VII - Adjustments and servicing proceduresAirfilter ..............................................................................................................................83Aircooler ...........................................................................................................................83Drivemotor .......................................................................................................................84Safety valve .......................................................................................................................84Beltsetexchangeandtensioning .....................................................................................85Cleaning the compressor element ....................................................................................85Replacement of the outlet pipe ........................................................................................87Dryermaintenance ............................................................................................................88

Section VIII - Problem solving .......................................................................89

Section IX - Technical data

Electriccablesizeandfuses ..............................................................................................91

Reference conditions and limitations ................................................................................97

Compressor data ...............................................................................................................98

Section X - Guidelines for inspection .........................................................102Section XI - PED (Pressure Equipment Directive) .......................................103Section XII - Declaration of conformity .......................................................104Standard Terms and Conditions ..................................................................106

Section I - General Information

Quincy Compressor 1

• Safety Alert Symbols• Safety Precautions• Spare Parts Ordering Information• Serial/Model Identification Plate• Royal Blue Warranty

Safety Alert Symbols

DANGER!

This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage.

DANGER!

This symbol identifies life threatening electrical voltage levels which will result in severe personal injury or death. All electrical work must be performed by a qualified electrician.

CAUTION!

This symbol identifies hot surfaces which could result in personal injury or property damage.

IMPORTANT!

Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness:

WARNING!

This symbol identifies hazards or unsafe practices which could result in personal injury, death or substantial property damage.

CAUTION!

Identifies hazards or unsafe practices which could result in minor personal injury or property damage.

NOTICE!Identifies important installation, operation or maintenance information which is not hazard related.


2 Quincy Compressor

Safety Precautions

Read this manual and follow all instructions prior to installing or operating the compressor.

Listed below are some, but not all, safety precautions that must be observed with compressors and compressed air systems.

WARNING!

Failure to follow any of these precautions may result in severe personal injury, death, property damage and/or compressor damage.

•Airfromthiscompressorwillcausesevere injury or death if used for breathingorfoodprocessing.Airused for these processes must meetOSHA29CFR1910.134orFDA21XDE178.3570regulations.

•Disconnectandlockoutallpowersupplies to the compressor plus any remote controllers prior to servicing the unit.

•Neverassumeitissafetoworkonthecompressor because it is not operating. Many installations have automatic start/stop controls and the compressor may start at any time.

•Thiscompressorisdesignedforuseinthe compression of normal atmospheric aironly.Noothergases,vaporsorfumes should be exposed to the compressorintake,norprocessedthrough the compressor.

•Relieveallpressureinternaltothecompressorpriortoservicing.Donotdependoncheckvalvestoholdsystempressure.

•Aproperlysizedpressurereliefvalvemust be installed in the discharge piping ahead (upstream) of any shutoff valve(blockvalve),heatexchanger,orificeoranypotentialblockagepoint.Failuretoinstallapressurerelief valve could result in the rupturing or explosion of some compressor component.

•Donotchangethepressuresettingofthe pressure relief valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with aplug.Overpressurizationofsystemor compressor components can occur, resulting in death, severe personal injury or property damage.

•Neveruseplasticpipe,rubberhose,or soldered joints in any part of the compressedairsystem.Failuretoensure system compatibility with compressor piping is dangerous.

•Neveruseaflammableortoxicsolventfor cleaning the air filter or any parts.

•Donotremoveanyguardsorcabinetpanels or attempt to service any compressor part while the compressor is operating.

•Donotoperatethecompressoratpressures in excess of its rating.

•Observecontrolpaneldisplaysdailyto ensure compressor is operating properly.

•Followallmaintenanceproceduresandcheckallsafetydevicesonschedule.

•Neverdisconnectortamperwiththehighairtemperature(HAT)sensors.

•Compressedairisdangerous,donotplay with it.


Quincy Compressor 3

•Usethecorrectfluidatalltimes.

•Donotrelyonthedischargeairlinecheckvalve.

•Donotoverrideanysafetyorshutdowndevices.

•Keepdoorsclosedduringoperation.Theoperatingtemperatureofsomecomponents is sufficient to burn the skin.

NOTICE!These instructions, precautions and descriptions cover standard Quincy manufactured QSI® Series air compressors. As a service to our customers, we often modify or construct packages to the customers specifications. This manual may not be appropriate in those cases.

NOTICE!Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy Compressor® reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors.

Spare Parts Ordering Information

Quincy Compressor maintains replacement parts for Quincy compressors and accessories.Arepairpartslistisshippedwith all new machines. Order parts from yourAuthorizedQuincydistributor.Useonly genuine Quincy replacement parts. Failuretodosomayvoidwarranty.

Serial/Model Identification Plate

ReferencetothemachineMODEL,SERIALNUMBERandDATEOFORIGINALSTART-UPmustbemadeinallcommunicationrelativetopartsorders.Amodel/serialnumber plate is located on the frame or in the upper right corner of the control panel door.


4 Quincy Compressor

WarrantyQuincyCompressor®IndustrialScrollProducts

QOF(2-30horsepowerONLY)BeltDriveCompressors

(Operatingat145PSIGfullloadpressureorless)

Standard Warranty

Quincy Compressor (Seller) warrants products of its own manufacture against defects in workmanshipandmaterialsundernormaluseandservice,asfollows:

Packaged Compressors -Twelve(12)monthsfromdateofstart-uporeighteen(18)monthsfrom date of shipment from the factory, whichever occurs first.

Section II - Description

Quincy Compressor 5

• General description• Flow diagram• Regulating system• Electrical system• Electric diagram• Temperature protection• Air dryer

General descriptionIntroduction

QOF20,QOF22andQOF30arestationary,oilfreecompressors.

Dependentonthemodel,thecompressorshave3or4electricmotordrivencompressormodules,enclosedinasoundinsulatingcanopy.Thefrontdoorpanelhousesthecontrollerwithgraphicaldisplayandtheemergencystopbutton.Anelectriccabinetwiththeelectriccomponents is located behind the front panel.

Thecompressorscanbedeliveredwithorwithoutintegratedrefrigerantairdryer.

QOFisthetypedesignationofthecompressorvariantwithoutintegrateddryer.OnQOF,thecompressedairofeachcompressormoduleflowsviaanindividualcheckvalvetoacommon air cooler and leaves the compressor via the air outlet valve.

QOFwithdryercompressorsareQOFcompressorsprovidedwitharefrigerantairdryer,integratedinthebodywork.

Thedryerremovesmoisturefromthecompressedairbycoolingtheairtonearfreezingpoint and automatically draining the condensate.

QOF 30 with dryer, front view


6 Quincy Compressor

1 Electroniccontroller S3 Emergencystopbutton2 Hour meter

QOF 30 with dryer, rear view

1 Compressor module 3 Refrigerant dryer2 Aircooler 4 Compressed air outlet valve

Compressor element operating principle

Eachcompressorelementconsistsofafixedscrollshapedhousingandascrollshapedrotor.Airentersthecompressorelementthroughinletopening(1).Oncetheairisdrawnin,theorbitingscroll(4)sealstheinletopeningandforcestheairintoacontinuouslydecreasingspace.Asscroll(4)keepsorbiting,thisprocessofcompressionisconstantlyrepeated,resultingindischargingofoilfreecompressedairthroughoutletopening(3).


Quincy Compressor 7

Compressor element, typical

1 Airinlet 3 Airoutlet2 Fixedscroll 4 Orbiting scroll

Compressor module

TheQOF20hasfour3.7kWmodules,whiletheQOF22andtheQOF30respectivelyhavethreeorfour5.5kWmodules.

3.7 kW compressor module


1 Airfilter 4 Compressor element air outlet2 Motor 5 Safety valve3 Compressor element 6 Temperaturesensor


8 Quincy Compressor

Flow diagram

Flow diagram


Quincy Compressor 9

Textonimage

(1) Compressor module 1 (10) Air(2) Compressor module 2 (11) Drain(3) Compressormodule3 (12) Mechanicallink(4) Compressormodule4 (13) Electricalsignal

(5) Tocubicle (14) Electricenergy

(6) Refrigerant dryer (units with dryer) (15) Enclosure

(7) Waterseparator(unitswithoutdryer) (16) Local mounting

(8) Outlet (17) On control cabinet

(9) Ambienttemperaturesensor

Air flow

Airisdrawnthroughairfilter(100)andiscompressedbythecompressorelement(102)ofeachcompressormodule.Thecompressedairisdischargedviathecheckvalve(104)and a common air cooler (112).

On compressors without integrated dryer, the compressed air passes a water separator (111) and flows to the outlet valve (121).

On standard compressors with an integrated air dryer, the compressed air flows through acommonrefrigerantdryer(300)beforereachingtheoutletvalve(121).Fordetailsonthe operation of the dryer, see section Refrigerant dryer.

Cooling

Eachcompressorelement(102)iscooledbyaradialfan(124),mountedonthedriveshaftofthecompressorelement.Thecoolingairisblownoverthecompressorelementvia a duct.

Aseparateelectricfan(130)providescoolingairforthecommonaircooler(112).

Condensate management

Thewaterseparator(111)oncompressorswithoutintegrateddryerhasanautomaticcondensate outlet and a manual drain valve.

On compressors with integrated dryer, the dryer is equipped with a water trap with an automatic condensate outlet and a manual drain valve.

Condensate drain connections (typical)


10 Quincy Compressor

1 Automaticcondensatedrainoutlet 3 Manual condensate drain valve2 Ambienttemperaturesensor

Regulating systemThecompressorisprovidedwithanelectroniccontrollermodule.

Thecontrollerperformsfollowingfunctions:

•Monitoringthepressure

•Protectingthecompressor

•Monitoringcomponentssubjecttoservice

•Automaticrestartaftervoltagefailure

Formoredetails,pleaseconsultthesectionsonthecontrollerfurtherinthisbook.

Electrical system

Cubicle layout

Electrical cabinet QOF 20, QOF 22 and QOF 30, typical

K21,K22,... Contactor 1X0,4X3,... TerminalsQ21,Q22,... Circuitbreaker T1,T4,... TransformerF1,F2,... Fuses


Quincy Compressor 11

Electric diagram

NOTICE!• The electrical installation must correspond to the applicable codes.• The mains supply and earthing lines must be of suitable size. See section Electriccable size and fuses.• The installation must be earthed and protected by fuses in each phase.• An isolating switch must be installed near the compressor. Make sure that this switchis open to isolate the compressor from the mains before carrying out any connection.

Thecompleteelectricaldiagramisavailableintheelectriccubicleofthecompressor.Forconnectionofthesupplywires,pleaseseesectionElectricalconnections.

Temperature protectionThecompressorisequippedwithanambienttemperaturesensor.Thesensorcreatesawarningmessageonthecontrolleriftheambienttemperaturerisesabove40°C(104°F).Iftheambienttemperaturereaches45°C(113°F),thecompressorisstopped.

Condensate drain connections

1 Automaticcondensatedrainoutlet 3 Manual condensate drain valve2 Ambienttemperaturesensor

EachcompressorelementisprotectedbyaPT1000sensor(6)intheoutletpipe.Thesensor is connected to the electronic regulator.

Whenthemaximumtemperatureisexceeded,thecompressorelementisstoppedduring2minutesbeforeitcanrestart.Ifthishappens2timeswithinatimespanof2hours,theelementwillbestoppedduring10minutes.

Ifthecompressorelementstopsathirdtimewithinthe2hourstimespan,theelementwill be shut down and must be reset manually.





CAUTION!

When the compressor is stopped due to overheating, the compressor will not restart until the failure is acknowledged and the compressor is restarted manually. See also sections Shutdown warning and Shutdown.

Air dryerFlow diagram



Compressed air circuit

Compressed air enters heat exchanger (1) and is cooled by the outgoing, cold, dried air. Waterintheincomingairstartstocondense.Theairthenflowsthroughheatexchanger/evaporator (2) where the refrigerant evaporates, causing the air to be cooled further to close to the evaporating temperature of the refrigerant. More

waterintheaircondenses.Thecoldairthenflowsthroughseparator(3)whereallthecondensate is separated from the air.

Thecold,driedairflowsthroughheatexchanger(1)whereitiswarmedupbytheincoming air.

Thecondensateisautomaticallydrainedbytheelectroniccondensatedrain(9).

Refrigerant circuit

Compressor(4)delivershot,high-pressurerefrigerantgaswhichflowsthroughcondenser(6) where most of the refrigerant condenses.

Theliquidflowsthroughliquidrefrigerantdryer/filter(7)tocapillarytube(8).Therefrigerant leaves the capillary tube at evaporating pressure.

Therefrigerantentersevaporator(2)whereitwithdrawsheatfromthecompressedairbyfurtherevaporationatconstantpressure.Theheatedrefrigerantleavestheevaporatorandissuckedinbythecompressor.

Thecondenser(6)pressuremustbekeptasconstantaspossibletoobtainstableoperation.Fancontrolswitch(P)thereforestopsandstartsthecondensercoolingfan.If,underpartialornoload,theevaporator(2)pressuredropstoapproximately2.25bar(e)(32.63psig),thehotgasbypassvalve(5)opensandhot,high-pressuregasisfedtotheevaporator circuit to prevent the evaporator pressure from dropping any further.

Automatic drain

Thedryersareequippedwithanelectroniccondensatedrain(EWD).Thecondensatefromthecondensatetrapaccumulatesinacollector.Whenthecondensatereachesacertain level, it is discharged through the drain outlet (1).

Thecondensatecanalsobedrainedbypressingthetestbutton(2).

Thedrainfiltercanbecleanedbyopeningthemanualdrainvalve(3),seesectionPreventivemaintenanceschedule.

Section III - Controller


• General• Control panel• Icons used• Main screen• Calling up menus• Shutdown warning• Shutdown• Inputs menu• Outputs menu• Counters• Control mode selection• Service menu• Setpoint menu• Event history menu• General settings menu• Info menu• Week timer menu• Test menu• User password menu• Web server• Programmable settings

GeneralControl panel

Introduction

Thecontrollerhasfollowingfunctions:

•Controllingthecompressor

•Protectingthecompressor

•Monitoringcomponentssubjecttoservice

•Automaticrestartaftervoltagefailure(madeinactive)

Automatic control of the compressor operation

Thecontrollermaintainsthenetpressurebetweenprogrammablelimitsbyautomaticallystartingandstoppingoneormorecompressormodules.Anumberofprogrammablesettings, e.g. the starting and stopping pressures and the maximum allowed motor



startingfrequencyandseveralotherparametersareherebytakenintoaccount.

Thecontrollerstopsthecompressorwheneverpossibletoreducethepowerconsumption and restarts it automatically when the net pressure decreases.

CAUTION!

A number of time based automatic start/stop commands can be programmed. Take into account that a start command will be executed (if programmed and activated),

even after manually stopping the compressor.

Protecting the compressor

ShutdownSeveralsensorsareprovidedonthecompressor.Ifoneofthemeasuredsignalsexceedstheprogrammedshutdownlevel,thecompressorwillbestopped.Thiswillbeindicatedondisplay(1)andgeneralalarmLED(2)willblink.

Remedythetroubleandresetthemessage.SeealsosectionInputsmenu.

CAUTION!

Before remedying, consult the applicable safety precautions.

Shutdown warning / shutdownIfthecompressorelementtemperatureexceedsthefactorysetwarninglevel,thecompressor element will be stopped for a short time and a warning will appear on the controllerdisplay(1)andthegeneralalarmLED(2)willlightup.

Incaseofrepetitivestopsduetoatoohightemperature,amanualresetwillbenecessary before restarting the compressor.

Thecompressorwillalsobestoppedwhenthemotorisoverloaded.

Awarningmessagewillalsoappearif,oncompressorswithintegrateddryer,thedewpoint temperature is too high in relation to the ambient temperature.

Service warning

Anumberofserviceoperationsaregrouped(calledServicePlans).EachServicePlanhasaprogrammedtimeinterval.Ifatimeintervalisexceeded,amessagewillappearondisplay (1) to warn the operator to carry out the service actions belonging to that Service Plan.

Therunninghourswillberecalculatedwithrespecttotheambienttemperature.Thisalgorithmisactivatedwhenthecompressorisoperatedabove30°C(86°F)ambient.

Automatic restart after voltage failure

Thecontrollerhasabuilt-infunctiontoautomaticallyrestartthecompressorwhenthevoltageisrestoredaftervoltagefailure.Forcompressorsleavingthefactory,thisfunctionismadeinactive.Ifdesired,thefunctioncanbeactivated.

Consult your supplier if a change is considered (password protected function).



CAUTION!

Ifthefunctionisactivatedandprovidedtheregulatorwasintheautomaticoperationmode, the compressor will automatically restart if the supply voltage to the module

is restored within the programmed time interval.

Control panel

Parts and functions

Reference Designation Function1 Display Shows the compressor operating condition and a

number of icons to navigate through the menu.2 Pictograph Automaticoperation3 Pictograph Generalalarm4 AlarmLED Flashesincaseofashutdown,islitincaseofawarn-

ing condition.5 Pictograph Service6 ServiceLED Lights up if service is needed7 AutomaticoperationLED Indicatesthattheregulatorisautomaticallycontrol-

ling the compressor. Thecompressorisstoppedandrestarted

8 VoltageonLED Indicatesthatthevoltageisswitchedon.9 Pictograph Voltage10 Enterkey Usethisbuttontoconfirmthelastaction.11 Escapekey Usethisbuttontogotopreviousscreenortoend

the current action.12 Scrollkeys Keystoscrollthroughthemenu.13 Stop button Buttontostopthecompressor.LED(7)goesout.14 Start button Buttontostartthecompressor.LED(7)lightsupindi-

cating that the controller is operative.



Icons usedStatus icons

Name Icon DescriptionStopped / Running Whenthecompressorisstopped,theiconstandsstill.

Whenthecompressorisrunning,theiconisrotating.

Compressor status Motor stopped

Motor running

Machine control mode

Or

Local start / stop

Remote start / stop

Networkcontrol

Automaticrestartafter voltage failure

Automaticrestartaftervoltagefailureisactive

Weektimer Weektimerisactive



Activeprotectionfunctions

Emergencystop

Shutdown

Warning

Service Service required

Main screen display Value lines display icon

Chart display icon

Generalicons Nocommunication/networkproblem

Notvalid

Input icons

Icon DescriptionPressure

Temperature

Digitalinput



Special protection

System icons

Icon DescriptionCompressorelement(LP,HP,...)

Dryer

Fan

Drain

Filter

Motor

Failureexpansionmodule

Networkproblem

Generalalarm

Thecompressormoduleisrunningandcanbestopped



Thecompressormoduleisstoppedandisreadytostart

Thecompressormoduleisawaitingtheminimumstoptimetoexpire

Menu icons

Icon DescriptionInputs

Outputs

Alarms(Warnings,shutdowns)

Counters

Or

Test

Settings

Service



Eventhistory(saveddata)

Accesskey/Userpassword

Network

Setpoint

Info

Navigation arrows

Icon DescriptionUp

Down



Main screenControl panel

1 Scrollkeys 3 Escapekey2 Enterkey

Function

TheMainscreenisthescreenthatisshownautomaticallywhenthevoltageisswitchedonandoneofthekeysispushed.Itisswitchedoffautomaticallyafterafewminuteswhennokeysarepushed.

Typically,6differentmainscreenviewscanbechosen:

1.Twovaluelines

2.Fourvaluelines

3.Chart(Highresolution)

4.Chart(Mediumresolution)

5.Chart(Lowresolution)

6. Scroll animation

Two and four value lines screens

ThistypeofMainscreenshowsthevalueof2or4parameters(seesectionInputsmenu).

Typical Main screen (2 value lines)



Textonimage

(1) Compressor Outlet(2) AmbientAir(3) Load, Shutdown, ... (text varies upon the compressors actual condition)(4) Menu

Typical Main screen (4 value lines), fixed speed compressors

Textonimage

(1) Compressor Outlet(2) Element2Outlet(3) Off, Shutdown,... (text varies upon the compressors actual condition(4) Menu(5) Element1Outlet(6) AmbientAir

•SectionAshowsinformationregardingthecompressoroperation(e.g.theoutletpressure, the ambient temperature or the temperature at one of the compressor element outlets).

•SectionBshowsStatusicons.Followingicontypesareshowninthisfield:

•FixediconsTheseiconsarealwaysshowninthemainscreenandcannotbeselectedbythe

cursor (e.g. Compressor stopped or running).•OptionaliconsTheseiconsareonlyshowniftheircorrespondingfunctionisactivated(e.g.week

timer, automatic restart after voltage failure , etc.)•PopupiconsTheseiconspopupifanabnormalconditionoccurs(warnings,shutdowns,service,...)Tocallupmoreinformationabouttheiconsshown,selecttheiconconcernedusing

thescrollkeysandpresstheenterkey.•Section C is called the Status bar

Thisbarshowsthetextthatcorrespondstotheselectedicon.



•Section DshowstheActionbuttons.Dependingonthesituation,thesebuttonsareused:

•Tocalluporprogramsettings

•Toresetamotoroverload,servicemessageoremergencystop

•Tohaveaccesstoalldatacollectedbytheregulator

Thefunctionofthebuttonsdependsonthedisplayedmenu.Themostcommonfunctionsare:

Designation FunctionMenu TogotothemenuModify TomodifyprogrammablesettingsReset Toresetatimerormessage

Toactivateanactionbutton,highlightthebuttonbyusingtheScrollkeysandpresstheEnterkey. Togobacktothepreviousmenu,presstheEscapekey.

Chart views

Insteadofviewingvalues,itisalsopossibletoviewagraphofoneoftheinputsignals(seesectionInputsmenu)infunctionofthetime.

WhenChart(HighResolution)isselected,thechartshowsthevariationoftheselectedinput(inthiscasethepressure)perminute.Alsotheinstantaneousvalueisdisplayed.Thescreenshowsthelast4minutes.

Theswitchbutton(icon)forselectingotherscreensischangedintoasmallChartandishighlighted (active).



WhentheChart(MediumResolution)isselected,thechartshowsthevariationoftheselectedinputperhour.Thescreenshowsthelast4hours.

WhentheChart(LowResolution)isselected,thechartshowsthevariationoftheselectedinputperday.Thescreenshowstheevolutionoverthelast10days.

Selection of a main screen view

Tochangebetweenthedifferentscreenlayouts,selectthefarrighticoninthecontroliconsline(seevaluelinesdisplayiconorchartdisplayiconinsectionIconsused)andpresstheEnterkey.Ascreensimilartotheonebelowopens:

SelectthelayoutrequiredandpresstheEnterkey.SeealsosectionInputsmenu.



Calling up menusControl panel

1 Scrollkeys 3 Escapekey2 Enterkey

Procedure

Whenthevoltageisswitchedon,theMainscreenisswitchedonautomatically:

TypicalMainscreen(2valuelines)

•TogototheMenuscreen,selectactionbuttonMenu(1)bymeansoftheScrollkeysandpresstheEnterkey.

Followingscreenappears:



Textonimage

(1) Menu(2) Regulation

•Themenuscreenshowsanumberoficons.Eachiconindicatesamenuitem.Bydefault,theRegulationiconisselected.Thestatusbarshowsthenameofthemenuthatcorresponds with the selected icon.

•UsetheScrollkeystoselecttherequiredicon(seefurther).PressingtheEscapekeyreturns to the Main screen.

Shutdown warningDescription

Ashutdownwarningwillappearintheeventof:

•Toohighelementtemperature•Toohighambienttemperature•Toohighdewpointtemperature(oncompressorswithintegratedrefrigerantdryer)

High element temperature

Whenacompressorelementtemperatureexceedsthewarninglevel,theelementstopsduringaMinimumStopTime.Itwillberestartedautomaticallyafterthistimehaselapsed and if the temperature is below this limit.

Aslongastheelementisstopped,anhourglassicon(1)replacestheelementconcernedinthemainscreen:

Element 2 is stopped during a Minimum Stop Time due to a high element temperature

Iftheelementtemperatureexceedsthefactorysetshutdownwarningrepeatedly,theelementwillshutdown,alarmLED(4)(seesectionControlpanel)willlitandfollowingscreenwillappear:



Element 2 is shutdown due to repeatedly high element temperature warnings

Ifthisoccurs:

1. Switch off the voltage and remedy the problem cause.

2. Switch on the voltage and reset the element manually by selecting the warning icon (orgotowarningmenu-elements)andpressReset:

Warning element screen (element 2 is triggered)

Textonimage

(1) Element(s)(2) WarningElement2(3) Triggered(4) ProblemElement(5) More(6) Reset

Eachtimeanelementisresetmanually,thiswillbeloggedintheElementProblemResetcounter:



Counter screen where one element was reset manually

Textonimage

(1) Information(2) Triggerlevel(3) HighTemperatureWarnings(4) ElementWarnings(5) ElementProblemResets(6) Modify

High ambient temperature

Iftheambienttemperatureisabovethefactorysetting(40°C-104°F),awarningistriggeredandawarningicon(1)isshownonthemainscreen:

Main screen with high ambient temperature warning

Textonimage

(1) Compressor outlet (pressure)(2) Warningicon(3) Load(4) Menu

Ifthiswarningistriggered,thedescriptionofthiswarningcanbefoundintheprotectionmenu.Followingscreenisshown:



Description of high ambient alarm in the protection menu

Textonimage

(1) General(2) Ambientair(3) HighTemperatureWarnings(4) Shutd.Warn.(5) Shutdown

Dew point temperature

Oncompressorswithintegrateddryer,alarmLED(4)willbelitandtherelatedalarmiconwillbeflashingifthedewpointemperatureexceedsthewarninglevel:

Main screen with dew point exceeding the limit

Textonimage

(1) Compressor outlet (pressure)(2) Warningicon(3) Load(4) Menu

GototheInputmenutoseetheactualdewpointtemperature.PresstheStopbutton(13-seesectionControlpanel)tostopthecompressor,switchoffthevoltage,inspectthe compressor and remedy if necessary.Thewarningmessagewilldisappearassoonthewarningconditiondisappears.



ShutdownDescription

Thecompressorwillshutdownincaseof:

•Toohighambienttemperature

•Motoroverload

•Outletpressuresensorerror

High ambient temperature

Iftheambienttemperatureisabovethefactorysetshutdowntemperature(45°C-113°F),thecompressorwillbestoppedandastopiconwillbeshownonthemainscreenofthecontroller:

Main screen - shutdown by too high ambient temperature

Textonimage

(1) Compressor outlet (pressure)(2) Stop icon(3) Shutdown(4) Menu

Motor overload

Amotoroverloadrelayprotectsthemotorofeachcompressormodule.Themotorisshutdown if the motor current is too high.



Inputs menuMenu icon, Inputs

Function

•Todisplaytheactualvalueofthemeasureddata(analoginputs)andthestatusofthedigital inputs (e.g. emergency stop contact, motor overload relay, etc.).

•Toselectthedigitalinputtobeshownonthechartinthemainscreen.

Procedure

Starting from the Main screen,

•MovethecursortotheactionbuttonMenuandpresstheEnterkey.Followingscreenappears:

Textonimage


•UsingtheScrollkeys,movethecursortotheInputsicon(seeabove,sectionMenuicon).

•PresstheEnterkey.Ascreensimilartotheonebelowappears:

Textonimage

(1) Inputs(2) Compressor outlet



(3) Elementoutlet(4) Ambientair(5) Emergencystop(Closed)

•Thescreenshowsalistofallinputswiththeircorrespondingiconsandreadings.

•Ifaninputisinwarningorshutdown,theoriginaliconisreplacedbythewarningorshutdowniconrespectively(theStopiconandtheWarningiconinthescreenshownabove).

Asmallcharticon,shownbelowaniteminthelistmeansthisinputsignalisshownonthechartatthemainscreen.Anyanaloginputcanbeselected.

Selecting another input signal as main chart signal

WiththeModifybuttonactive(lightgreybackgroundinabovescreen),presstheEnterbuttononthecontroller.Ascreensimilartotheonebelowappears:

Thefirstiteminthelistishighlighted.Inthisexample,theNetPressureisselected(charticon).

Tochange,presstheEnterbuttonagain.Apopupwindowopens:

PressEnteragaintoremovethisinputfromthechart.Anotherconfirmationpopupopens:



SelectYestoremoveorNotoquitthecurrentaction. Inasimilarway,anotherinputsignalcanbehighlightedandselectedasMainChartsignal:

Textonimage

(1) SetAsMainChartSignal



Outputs menuMenu icon, Outputs

Function

TocallupinformationregardingtheactualstatusofsomeoutputssuchastheconditionoftheFanmotoroverloadcontact,thegeneralwarningcontact,etc.

Procedure



Textonimage


•UsingtheScrollkeys,movethecursortotheoutputsicon(seeabove).

•PresstheEnterkey.Ascreensimilartotheonebelowappears:

Outputs screen (typical)

Textonimage

(1) General(2) Generalshutdown(3) Fanmotor



(4) Generalwarning(5) Cabinet fan

•Thescreenshowsalistofalloutputswiththeircorrespondingiconsandreadings.Ifan output is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively.

CountersMenu icon, Counters

Function

Tocallup:

•Therunninghours

•Theloadedhours

•Thenumberofmotorstarts

•Thenumberofhoursthattheregulatorhasbeenpowered

•ThenumberofloadcyclesProcedure

Starting from the Main screen,•UsingtheScrollkeys,movethecursortotheactionbuttonMenuandpresstheEnterkey.Followingscreenappears:

Textonimage


•UsingtheScrollkeys,movethecursortotheCountersicon(seeabove).

•PresstheEnterkey.Followingscreenappears:



Textonimage

(1) Counters(2) Shutdowns element 2(3) Load relay(4) Fanstarts(5) Module hours

Thescreenshowsalistofallcounterswiththeiractualreadings.

Control mode selectionFunction

Toselectthecontrolmode,i.e.whetherthecompressorisinlocalcontrol,remotecontrolorcontrolledviaalocalareanetwork(LAN).

Procedure

• Starting from the Main screen, make sure action button Menu (1) is selected:

Textonimage

(1) Menu

•Next,usethescrollbuttonstogotothecontrolmodeicon(2)andpresstheEnterkey(seesectionIconsusedforthemeaningoftheicons):



•Thereare3possibilities:

•Localcontrol(1)•Remotecontrol(2)•LANcontrol(3)

Afterselectingtherequiredcontrolmode,presstheEnterkeyonthecontrollertoconfirmyourselection.Thenewcontrolmodeselectionisnowvisibleonthemainscreen.



Service menuMenu icon, Service

Function

•Toresettheserviceplanswhicharecarriedout.

•Tocheckwhenthenextserviceplansaretobecarriedout.

•Tofindoutwhichserviceplanswerecarriedoutinthepast.

•Tomodifytheprogrammedserviceintervals.

Procedure



Textonimage


•UsingtheScrollkeys,movethecursortotheServiceicon(seeabove,sectionMenuicon).




Textonimage

(1) Service(2) Overview(3) Service plan(4) Nextservice(5) History

•ScrollthroughtheitemstoselectthedesireditemandpresstheEnterkeytoseethedetails as explained below.

Overview

Textonimage

(1) Overview(2) Running Hours(3) RealTime(hours)(4) Reset

Exampleforservicelevel(A):

Thefiguresattheleftaretheprogrammedserviceintervals.ForServiceintervalA,theprogrammednumberofrunninghoursis500hours(upperrow)andtheprogrammednumberofrealtimehoursis2190hours,whichcorrespondstooneyear(secondrow).Thismeansthatthecontrollerwilllaunchaservicewarningwheneither500runninghoursor2190realhoursarereached,whichevercomesfirst.Notethattherealtimehourscounterkeepscounting,alsowhenthecontrollerisnotpowered.

Anewalgorithmisimplementedforabetterprotectionofthecompressorelements.Therunninghourswillberecalculateddependingontheambienttemperature.Acompressorcontinuouslyrunninginanambienttemperaturebetween30°C(86°F)and35°C(95°F)isworkinginharderconditionsthananelementrunningat20°C(68°F).Thereforeaservicedoneearlier(atimereductionof30%isappliedinthistemperaturezone)willprotecttheelementinabetterway.Inthezonebetween35°C(95°F)and40°C(104°F),thetimereductionis60%.

Thefigureswithinthebarsarethenumberofhourstogotillthenextserviceintervention.Intheexampleabove,thecompressorwasjuststartedup,whichmeansitstillhas500runninghoursor2187hourstogobeforethenextServiceintervention.

Service plans

Anumberofserviceoperationsaregrouped(calledLevelA,LevelB,etc...).Each



level stands for a number of service actions to be carried out at the time intervals programmed in the controller.

Whenaserviceplanintervalisreached,amessagewillappearonthescreen.

Aftercarryingouttheserviceactionsrelatedtotheindicatedlevels,thetimersmustbereset.

FromtheServicemenuabove,selectServiceplan(3)andpressEnter.Followingscreenappears::

Textonimage

(1) Service plan(2) Level(3) Running hours(4) Real time hours(5) Modify

Modifying a service plan

Dependantontheoperatingconditions,itcanbenecessarytomodifytheserviceintervals.Todoso,usetheScrollkeystoselectthevaluetobemodified.Ascreensimilartotheonebelowappears:

PresstheEnterkey.Followingscreenappears:



Modify the value as required, using the ↑ or ↓scrollkeyandpresstheEnterkeytoconfirm.Note:Runninghourscanbemodifiedinstepsof100hours,realtimehourscanbemodified in steps of 1 hour

Next Service

Textonimage

(1) Nextservice(2) Level(3) Running hours(4) Actual

Intheexampleabove,theAServicelevelisprogrammedat500runninghours,ofwhich0hourshavepassed.

History

TheHistoryscreenshowsalistofallserviceactionsdoneinthepast,sortedbydate.Thedateatthetopisthemostrecentserviceaction.Toseethedetailsofacompletedserviceaction(e.g.Servicelevel,RunninghoursorRealtimehours),usetheScrollkeystoselectthedesiredactionandpresstheEnterkey.



Setpoint menuMenu icon, Setpoint

Function

Itispossibletoprogram2differentpressurebands.Thismenuisalsousedtoselecttheactive pressure band.

Procedure



Textonimage


•UsingtheScrollkeys,movethecursortotheSetpointicon(seeabove,sectionMenuicon)


Textonimage

(1) Regulation



(2) Pressureband1High(3) Pressureband1Low(4) Pressureband2High(5) Pressureband2Low(6) Modify

•Thescreenshowstheactualstoppingandstartingpressuresettingsforbothpressure bands. Tomodifythesettings,movethecursortotheactionbuttonModifyandpresstheEnterkey.Followingscreenappears:

•Thefirstlineofthescreenishighlighted.UsetheScrollkeystohighlightthesettingtobemodifiedandpresstheEnterkey.Followingscreenappears:

Textonimage

(1) Regulation(2) Stopping pressure

•Theupperandlowerlimitofthesettingisshowningrey,theactualsettingisshowninblack.Usethe↑ or ↓ keyoftheScrollkeystomodifythesettingsasrequiredandpresstheEnterkeytoaccept.

Ifnecessary,changetheothersettingsasrequiredinthesamewayasdescribedabove.



Event history menuMenu icon, Event History

Function

Tocallupthelastshutdownandlastemergencystopdata.

Procedure


•UsingtheScrollkeys,movethecursortotheactionbuttonMenuandpresstheEnterkey.Followingscreenappears:

Textonimage


•UsingtheScrollkeys,movethecursortotheEventHistoryicon(seeabove).

•PresstheEnterkey.Thelistoflastshutdownandemergencystopcasesisshown.

Example of Event History screen

•Scrollthroughtheitemstoselectthedesiredshutdownoremergencystopevent.

•PresstheEnterkeytofindthedate,timeandotherdatareflectingthestatusofthecompressor when that shutdown or emergency stop occurred.



General settings menuMenu icon, Settings

Function

Todisplayandmodifyanumberofsettings.

Procedure



Textonimage


•UsingtheScrollkeys,movethecursortotheSettingsicon(seeabove)•PresstheEnterkey.Followingscreenappears:

Thisscreenshowsagainanumberoficons.Bydefault,theUserPasswordiconisselected.Thestatusbarshowsthedescriptionthatcorrespondswiththeselectedicon.Eachiconcoversoneormoreitems,suchas

•Accesslevel•Elements•Dryer



•Fan•Filter(s)•Motor/Starter•General•Automaticrestartaftervoltagefailure•Network•Regulation•RemoteForadaptingcertainparameters,apasswordmaybenecessary.

Example:SelectingtheGeneralSettingsicongivesthepossibilitytochangee.g.thelanguage,thedate,thedateformat,etc.:

Textonimage

(1) General(2) LanguageInUse(3) Time(4) Date(5) DateFormat(6) Modify

•Tomodify,selecttheModifybuttonusingtheScrollkeysandpresstheEnterkey.

•Ascreensimilartotheoneaboveisshown,thefirstitem(Language)ishighlighted.Usethe↓keyoftheScrollkeystoselectthesettingtobemodifiedandpresstheEnterkey.

•Apopupscreenappears.Usethe↑ or ↓keytoselecttherequiredvalueandpresstheEnterkeytoconfirm.



Info menuMenu icon, Info

Function

ShowstheSPIRALAIRinternetaddress.

Procedure



Textonimage


•UsingtheScrollkeys,movethecursortotheInfoicon(seeabove,sectionMenuicon).

•PresstheEnterkey.Theinternetaddressappearsonthescreen.



Week timer menuMenu icon, Week timer

Function

•Toprogramtimebasedstart/stopcommandsforthecompressor.

•Toprogramtimebasedchangeovercommandsforthenetpressureband.

•Fourdifferentweekschemescanbeprogrammed.

•Aweekcyclecanbeprogrammed,aweekcycleisasequenceof10weeks.Foreachweekinthecycle,oneofthefourprogrammedweekschemescanbechosen.

Notice!

Important remark:You can select different timers on one day.(up to 8 actions). It is however not possible to program 2 actions at the same time. The solution: leave at least 1 minute in between 2 actions.

Example: Start Compressor: 5.00 AM, Pressure Setpoint 2: 5.01 AM (or later).

Procedure


•MovethecursortotheactionbuttonMenuandpresstheEnterkey.UsetheScrollbuttonstoselecttheTimericon.

Textonimage


•PresstheEnterkeyonthecontroller.Followingscreenappears:



Textonimage

(1) WeekTimer(2) WeekActionSchemes(3) WeekCycle(4) Status(5) WeekTimerInactive(6) RemainingRunningTime

Thefirstiteminthislistishighlighted.SelecttheitemtobeadaptedandpresstheEnterkeyonthecontrollertomodify.

Programming week schemes

•SelectWeekactionschemesandpressEnter.Anewwindowopens.Thefirstiteminthelistishighlightedinred.PresstheEnterkeyonthecontrollertomodifyWeekActionScheme1.

Textonimage

(1) WeekActionSchemes(2) WeekActionSchemes1(3) WeekActionSchemes2(4) WeekActionSchemes3(5) WeekActionSchemes4



•Aweeklylistisshown.Mondayisautomaticallyselectedandhighlightedinred.PresstheEnterkeyonthecontrollertosetanactionforthisday.

Textonimage

(1) WeekActionScheme1(2) Monday(3) Tuesday(4) Wednesday(5) Thursday(6) Friday(7) Saturday(8) Sunday

•Anewwindowopens.TheModifyactionbuttonisselected.Presstheenterbuttonon the controller to create an action.

Textonimage

(1) Monday(2) Modify

•Anewpopupwindowopens.SelectanactionfromthislistbyusingtheScrollkeysonthecontroller.WhenreadypresstheEnterkeytoconfirm.



Textonimage

(1) Monday(2) Actions(3) Remove(4) Start(5) Stop(6) PressureSetpoint1(7) Modify

•Anewwindowopens.Theactionisnowvisibleinthefirstdayoftheweek.

Textonimage

(1) Monday(2) Start(3) Save(4) Modify

•Toadjustthetime,usetheScrollkeysonthecontrollerandpresstheEnterkeytoconfirm.



•Anewpopupwindowopens.Usethe↑ or ↓keyofScrollkeystomodifythevaluesofthehours.Usethe← or →Scrollkeystogototheminutes.

Textonimage

(1) Monday(2) Time(3) Save(4) Modify

•PresstheEscapekeyonthecontroller.TheactionbuttonModifyisselected.UsetheScrollkeystoselecttheactionSave.

Textonimage

(1) Monday(2) Start(3) Save



(4) Modify

•Anewpop-upwindowopens.UsetheScrollkeysonthecontrollertoselectthecorrectactions.PresstheEnterkeytoconfirm.

Textonimage

(1) Monday(3) Areyousure?(4) No(5) Yes(6) Save(7) Modify(7) Modify

PresstheEscapekeytoleavethiswindow.

•Theactionisshownbelowthedaytheactionisplanned.

Textonimage

(1) WeekActionScheme1(2) Monday-Start(3) Tuesday(4) Wednesday(5) Thursday(6) Friday



(7) Saturday(8) Sunday

PresstheEscapekeyonthecontrollertoleavethisscreen.

Programming the week cycle

Aweekcycleisasequenceof10weeks.Foreachweekinthecycle,oneofthefourprogrammedweekschemescanbechosen.

•SelectWeekCyclefromthemainWeekTimermenulist.

Textonimage

(1) WeekTimer(2) WeekActionSchemes(3) WeekCycle(4) Status(5) WeekTimerInactive(6) RemainingRunningTime

•Alistof10weeksisshown.

Textonimage

(1) WeekCycle(2) Week1(3) Week2



(4) Week3(5) Week4(6) Modify

PresstheEnterkeytwicetomodifythefirstweek.

•Anewwindowopens.Selecttheaction,example:WeekActionScheme1

Textonimage

(1) WeekCycle(2) Week1(3) WeekActionScheme1(4) WeekActionScheme2(5) WeekActionScheme3(6) Modify

•CheckthestatusoftheWeekTimer

UsetheEscapekeyonthecontrollertogobacktothemainWeekTimermenu.SelectthestatusoftheWeekTimer.

Textonimage

(1) WeekTimer(2) WeekActionSchemes(3) WeekCycle(4) Status



(5) WeekTimerInactive(6) RemainingRunningTime

•Anewwindowopens.SelectWeek1tosettheWeekTimeractive.

Textonimage

(1) WeekTimer(2) Week(3) WeekTimerInactive(4) Week1

•PresstheEscapekeyonthecontrollertoleavethiswindow.Thestatusshowsthatweek1isactive.

Textonimage

(1) WeekTimer(2) WeekActionSchemes(3) WeekCycle(4) Status(5) RemainingRunningTime

•PresstheEscapekeyonthecontrollertogotothemainWeekTimermenu.SelectRemainingRunningTimefromthelistandpresstheEnterkeyonthecontrollertoModify.



•Thistimerisusedwhentheweektimerissetandforcertainreasonsthecompressormustcontinueworking,forexample,1hour,itcanbesetinthisscreen.ThistimerispriortotheWeekTimeraction.

Textonimage

(1) WeekTimer(2) WeekActionSchemes(3) RemainingRunningTime



Test menuMenu icon, Test

or

Function

•Tocarryoutadisplaytest,i.e.tocheckwhetherthedisplayandLED’sarestillintact.

Procedure


•MovethecursortotheactionbuttonMenuandpresstheEnterkey(2).Followingscreenappears:

•Usingthescrollkeys,movethecursortothetesticon(seeabove)

•PresstheEnterkey,followingscreenappears:

Textonimage

(1) Test(2) SafetyValveTest(3) Notallowed



(4) AuditData

•Thesafetyvalvetestcanonlybeperformedbyauthorizedpersonnelandisprotectedby a security code.

•Selecttheitemdisplaytestandpresstheenterkey.Ascreenisshowntoinspectthedisplay,atthesametimeallLED’sarelit.

User password menuMenu icon, Password

Function

Ifthepasswordoptionisactivated,itisimpossiblefornotauthorizedpersonstomodifyany setting.

Procedure



Textonimage


•UsingtheScrollkeys,selecttheSettingsicon(seesectionGeneralsettingsmenu).




•MovethecursortothePasswordicon(seeabove,sectionMenuicon)

•SelectModify,usingtheScrollkeysandpresstheEnterkey.Next,modifythepassword as required.

Web serverThecontrollerhasabuilt-inwebserverthatallowsdirectconnectiontothecompanynetworkortoadedicatedPCviaalocalareanetwork(LAN).ThisallowstoconsultcertaindataandsettingsviaaPCinsteadofonthedisplayofthecontroller.

Getting started

Makesureyouareloggedinasadministrator.

•UsetheinternalnetworkcardfromyourcomputeroraUSBtoLANadapter(seepicture below).

USB to LAN adapter

•UseaUTPcable(CAT5e)toconnecttothecontroller(seepicturebelow).



Configuration of the network card (in Windows)

•GotoMyNetworkplaces(1).

•ClickonViewNetworkconnections(1).

•SelecttheLocalAreaconnection(1),whichisconnectedtothecontroller.



•Clickwiththerightbuttonandselectproperties(1).

•UsethecheckboxInternetProtocol(TCP/IP)(1)(seepicture).Toavoidconflicts,uncheckotherpropertiesiftheyarechecked.AfterselectingTCP/IP,clickonthePropertiesbutton(2)tochangethesettings.

•Usethefollowingsettings:

•IPAddress192.168.100.200



•Subnetmask255.255.255.0ClickOKandclosenetworkconnections.

Configuration of the web server

Configurethewebinterface(forInternetExplorer)

•OpenInternetExplorerandclickonTools-Internetoptions(2).

•ClickontheConnectionstab(1)andthenclickontheLANsettingsbutton(2).

•IntheProxyserverGroupbox,clickontheAdvancedbutton(1).



•IntheExceptionsGroupbox,entertheIPaddressofyourcontroller.MultipleIPaddresses can be given but they must be separated with semicolons (;). Example:SupposethatyoualreadyaddedtwoIPaddresses(192.168.100.1and192.168.100.2).Nowyouadd192.168.100.100andseparatethe3IPaddressesbyputting semicolons between them (1) (see picture). ClickOK(2)toclosethewindow.



Viewing the controller data

NOTICE!All screen shots are indicative. The number of displayed fields depends on the

selected options.

•OpenyourbrowserandtypetheIPaddressofthecontrolleryouwanttoviewinyourbrowser(inthisexamplehttp://192.168.100.100).Theinterfaceopens:

Screen shot (typical)

Navigation and options

•Thebannershowsthecompressortypeandthelanguageselector.Inthisexample,three languages are available on the controller.



Compressor settings

Allcompressorsettingscanbedisplayedorhidden.Putacheckmarkinfrontofeachpoint of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen.

Analog inputs

Listsallcurrentanaloginputvalues.Themeasurementunitscanbechangedinthepreference button from the navigation menu.

Counters

Lists all current counter values from controller and compressor.

Info status

Machine status is always shown on the web interface.



Digital inputs

ListsallDigitalinputsandtheirstatus.

Digital outputs

ListsallDigitaloutputsandtheirstatus.

Special protections

Lists all special protections of the compressor.

Service plan

Displaysalllevelsoftheserviceplanandtheirstatus.Thisscreenshotunderneathonlyshowstherunninghours.Itisalsopossibletoshowthecurrentstatusoftheserviceinterval.



Programmable settingsCompressors without built-in refrigeration dryer

Minimum setting Factorysetting Maximum settingStarting pressure

Startingpressure(8barcom-pressors)

bar(e) 4 7 8


psig 58 101.5 116

Startingpressure(10barcompressors)

bar(e) 4 9 10


psig 58 130.5 145

Minimum setting Factorysetting Maximum settingStopping pressure

Stoppingpressure(8barcompressors)

bar(e) 4 8 8


psig 58 116 116


bar(e) 4 10 10


psig 58 145 145



Compressors with built-in refrigeration dryer

Minimum setting Factorysetting Maximum settingStarting pressure


bar(e) 4 6.8 7.8


psig 58 98.6 113.1


bar(e) 4 8.8 9.8


psig 58 127.6 142.1

Minimum setting Factorysetting Maximum settingStopping pressure


bar(e) 4 7.8 7.8


psig 58 113.1 113.1


bar(e) 4 9.8 9.8


psig 58 142.1 142.1

Parameters

Minimum setting Factorysetting Maximum settingAllowednumberofmotorstarts per day

72 720 720

Powerrecoverytime(Auto-matic restart function)

s 60 60 3600

Restart delay s 0 0 1200

Communicationtime-out s 10 30 60

Protections

Minimum setting Factorysetting Maximum settingAmbienttemperaturewarn-ing level

°C 0 40 40

Ambienttemperaturewarn-ing level

°F 32 104 104

Ambienttemperatureshut-down level

°C 0 45 45

Ambienttemperatureshut-down level

°F 32 113 113



Service plan

Thebuilt-inservicetimerswillgiveaServicewarningmessageaftertheirrespectivepre-programmed time interval has elapsed.AlsoseesectionPreventivemaintenanceschedule.Consultyoursupplierifatimersettinghastobechanged.Theintervalsmustnotexceedthe nominal intervals and must coincide logically. See section Service menu.Terminology

Term ExplanationARAVF AutomaticRestartAfterVoltageFailure.SeesectionGeneral.Powerrecoverytime

Istheperiodwithinwhichthevoltagemustberestoredtohaveanauto-maticrestart.Isaccessibleiftheautomaticrestartisactivated.Toactivatethe automatic restart function, consult your supplier.

Restart delay Thisparameterallowstoprogrammethatnotallcompressorsarerestartedatthesametimeafterapowerfailure(ARAVFactive).

Delayatshut-down signal

Isthetimeforwhichthesignalmustexistbeforethecompressorisshutdown.Ifitisrequiredtoprogramthissettingtoanothervalue,consultyoursupplier.

Minimum stop time

Once the compressor has automatically stopped, it will remain stopped for the minimum stop time, whatever happens with the net air pressure. Con-sultyoursupplierifasettinglowerthan20secondsisrequired.

Starting / stop-ping pressure

Theregulatordoesnotacceptinconsistentsettings,e.g.ifthestoppingpressureisprogrammedat7.0bar(e)(101psi(g)),themaximumlimitforthestartingpressurechangesto6.9bar(e)(100psi(g)).Therecommendedminimumpressuredifferencebetweenstartingandstoppingis0.6bar(9psi(g)).

Section IV - Installation guidelines


• Dimension drawing• Installation proposal• Electrical connections• Pictographs

Dimension drawingThedimensiondrawingscanbefoundontheCD,deliveredwiththecompressor.

Herebyalistofcommonlyusedtermswiththeirtranslation:

Text on drawings TranslationCooling air outlet of aftercooler and dryer Cooling air outlet of aftercooler and dryerCabinet ventilation Cabinet ventilationCooling air outlet of compressor Cooling air outlet of compressorElectriccablepassage ElectriccablepassageCompressed air outlet Compressed air outletManual drain Manual drainAmbientsensor AmbientsensorAutomaticdraintube AutomaticdraintubeCompressor mounting holes Compressor mounting holesCooling air inlet of aftercooler and dryer Cooling air inlet of aftercooler and dryerCooling air inlet of compressor and cabinet Cooling air inlet of compressor and cabinetCenter of gravity dimensions and mass Center of gravity dimensions and mass

Installation proposalOutdoor/altitude operation

NOTICE!If the compressor is installed outdoors or if the air inlet temperature can be below 0 °C (32 °F), precautions must be taken. In this case, and also if operating at high

altitude, consult your supplier.



Installation proposal

Reference Description1 Minimum free area to be reserved for the compressor installation2 Ventilation proposals

Procedure

1.Installthecompressoronalevelfloor,suitablefortakingtheweightofthecompressor in a frost free and preferably low dust location.

2. Compressed air outlet valve.

3.Deliverypipe.

Thepressuredropovertheairdeliverypipecanbecalculatedasfollows:

Δp=(Lx450xQc1.85) / (d5xP),with

d = inner diameter of the pipe in mm



Δp=pressuredropinbar(recommendedmaximum:0.1bar(1.5psi))

L = length of the pipe in m

P=absolutepressureatthecompressoroutletinbar

QC=Freeairdeliveryofthecompressorinl/s

4.Ventilation:Theinletgrid(s)andventilationfanshouldbeinstalledinsuchawaythatany recirculation of hot cooling air to the inlet gratings of the compressor/dryer is avoided.

Theairvelocitytothegrid(s)hastobelimitedto5m/s(16.5ft/s).

Maximumallowablepressuredropovercoolingairductsis50Pa(0.12inWC).

When50Paisexceeded,aventilationfanisneededattheoutletofthecoolingairducts.Themaximumairtemperatureatthecompressorintakeopeningis40°C(104°F),theminimumis0°C(32°F).

Alternative1and3:Therequiredventilationtolimitthecompressorroomtemperaturecan be calculated

from:

QV=0,92N/Δt

with

QV=requiredventilationcapacityinm3/s

N=nominalmotorpowerofthecompressorinkW

Δt=temperatureincreaseinthecompressorroomin°C

Alternative2and4:Thefancapacityshouldmatchthecompressorfancapacityatapressure head equal to the pressure drop caused by the cooling air ducts.

5.Controlcubiclewithmonitoringpanel.

6. Mains cable entry.

7.Optionalfilterscanbeinstalledinthepressurelinedownstreamtheairoutletvalve,e.g.:

•Afilterforgeneralpurposefiltration.Thefiltertrapssolidparticlesdownto1micron.

•Afilterforfiltrationdownto0.01micron.Thisfiltermustalwaysbeinstalleddownstream of the general purpose filter.

Itisrecommendedtoprovidebypasspipesandvalvesacrossthefiltersinorderto isolate the filters during maintenance without disturbing the compressed air delivery.

8.Safetyvalve.

9.Thedrainpipestothedrainmustnotdipintothewater.

10.Compressorcoolingairoutlet.

11. Ventilation outlet

12.Aftercooleranddryercoolingairoutlet.

13.Dataplate.



Electrical connectionsAttention

WARNING!

The electrical installation must correspond to the local codes. The mains supply and earthing lines must be of suitable size.

The installation must be earthed and protected by fuses in each phase. An isolating switch should be installed near the compressor.

Make sure that this switch is open to isolate the compressor from the mains beforecarrying out any connection.

To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment, it is mandatory to use a proper

cable gland when connecting the supply cable to the compressor.

Supply cable

ConsultsectionElectriccablesizeandfusesforthesectionofthepowersupplycable.

ConnectthesupplycabletoterminalsL1,L2andL3ofterminalstrip(1X0),connecttheneutralconductortoterminal(N)(ifapplicable)andtheearthingconductortotheearthingbolt(1X3).



PictographsPictographs

Pictographs

Reference Description1 Automaticcondensatedrain2 Warning:beforeconnectingcompressorelectrically,consultInstruction

bookformotorrotationdirection3 Consult the specific instructions before greasing4 Manual condensate drain5 Torquesforsteel(Fe)orbrass(CuZn)bolts6 Switchoffthevoltageanddepressurizethecompressorbeforemainte-

nance or repair7 Warning:voltage8 Warning:hotsurface9 Rotation direction of fan

Section V - Operating instructions


• Initial start-up• Starting• During operation• Stopping• Taking out of operation

Initial start-upSafety

CAUTION!

The operator must apply all relevant Safety precautions.

Initial start-up procedure

1.Removetheredpaintedtransportbrackets(2).

2.Checkthesettingsoftheoverloadrelays.SeesectionElectriccablesizeandfuses.

3.Connectthecompressorelectrically.SeesectionElectricalconnections.

4.Closethecondensatedrainvalve.SeechapterCondensatemanagementinsectionFlowdiagram.

5.Switchonthevoltage.Startandstopthecompressor.On3-phasecompressors,checkforcorrectdirectionofrotation(directionarrowsareprovidedonthemotors).Iftherotationdirectioniswrong,switchoffthevoltageandreversetwoincomingelectric lines.



StartingProcedure

1.Opentheairoutletvalve.SeesectionIntroductionforitslocation.

2. Switch on the voltage.

3.Closeallmanualcondensatedrainvalves.

4.Pressthestartbutton(1).ThecompressorstartsrunningandautomaticoperationLEDlightsup.

5.Theregulatorwillautomaticallystopandstartthecompressormodulesinfunctionof the air pressure.

6. On compressors with integrated dryer, the nominal pressure dew point will be reached after a few minutes.

NOTICE!The number of starts is limited to 30 starts per hour. See also section Programmable

settings.

During operation

Procedure

1. If the automatic operation LED (3) is alight, the regulator is automatically controlling the compressor modules (starting/stopping).

2. Check the readings on the display (1). In case of a warning or shutdown condition, see section Problem solving or Event history menu.



3. Check that condensate is discharged automatically from the condensate drain outlet during operation.

NOTICE!The dew point will deviate from nominal when the nominal conditions are exceeded.

If the dew point remains too high or unstable, consult section Problem solving.

StoppingProcedure

1.Pressthestopbutton(2).

2.Closetheairoutletvalve.SeesectionIntroduction.

3.Switchoffthevoltage.

4.Openthemanualcondensatedrainvalve.

Taking out of operationProcedure

1. Stop the compressor and close the air outlet valve.

2. Switch off the voltage and disconnect the compressor from the mains.

3.Depressurizethecompressor.Openthecondensatedrainvalve.

4.Shutoffanddepressurizethepartoftheairnetwhichconnectedtotheoutletvalve.Disconnectthecompressorfromtheairnet.

5.Disconnectthecondensatepipingfromthelocalcondensatedrainsystem.

Section VI - Maintenance


• Preventive maintenance schedule• Service kits• Disposal of used material

Preventive maintenance scheduleWarning

CAUTION!

Before carrying out any maintenance, repair work or adjustments, proceed as follows:• Stop the compressor.• Switch off the voltage and open the isolating switch.• Press the emergency stop button (S3).• Close the air outlet valve.• Depressurize the compressor by opening the manual drain valve(s).The operator must apply all relevant Safety precautions during maintenance or repair.

Warranty - Product Liability

Useonlyauthorizedparts.AnydamageormalfunctioncausedbytheuseofunauthorizedpartsisnotcoveredbyWarrantyorProductLiability.

General

Whenservicing,replaceallremovedgaskets,O-ringsandwashers.

Intervals

ThelocalCustomerCentremayoverrulethespecifiedmaintenanceschedule,especiallythe service intervals, depending on the environmental and operating conditions of the compressor.

NOTICE!The longer interval checks must always include the shorter interval checks.

Preventive maintenance schedule

AnumberofserviceoperationsaregroupedinplanscalledServiceplansI,A,BorD.Seethetablebelow.Amessagewillappearonthecontrollerdisplaywhenreachingtheinterval,indicatingwhichServiceplansaretobecarriedout.Afterservicing,theregulatoristobereset.Fordetailedinformation,consultsectionServicemenu.

Period (note 1)

Running hours (note 1)

Service Plan

Operation

Daily - - •Checkreadingsondisplay. •Checkifcondensateisdischargedduringoperation. •Draincondensatemanually(whenapplicable). •Oncompressorswithintegrateddryer:checkthedewpoint.

Every3months (note 2)

500 - •Checkthepressuredropoverthe(optional)filters. •Inspecttheairinletfilters:checkforcleannessanddam-age. Replace a dirty or damaged filter with a new one. •Checkthecoolers.Cleanbyairjetifnecessary.



Period (note 1)

Running hours (note 1)

Service Plan

Operation

Every6months

1000 - •Operatethesafetyvalve. •Cleanthecompressor. •Oncompressorswithintegrateddryer:•Brushorblowoffthefinnedsurfaceofthe

condenser.•Inspectandcleantheelectronicdrain: •FunctioningofthedraincanbecheckedbypushingtheTESTbuttonofthedrain. •Cleaningofthedrainfiltercanbedonebyopening the manual drain valve during a few seconds.

Yearly 2500 - •Replacetheairinletfilters. •Testthesafetyvalves. •Havetemperatureprotectionandmotoroverloadtested. •ChecktensionandconditionoftheV-belts.

Every2years

5000 A •ReplaceV-belt(s). •Replacethecheckvalves.

Every2years

5000 B 8barand116psicompressors: •Cleanfan(ref124onFlowdiagram),fanductandele-ment cooling fins (see note 2). See section Cleaning cooling fins. •Haveorbitingscrollbearinggreased(seenote3).

Every2years

5000 B 10barand145psicompressors: •Replacetheelementoutletpipeandtheplasticinsert.SeesectionOutletpipereplacement(3.7kWelementsonly). •Cleanfan(ref124onFlowdiagram),fanductandele-ment cooling fins (see note 2). See section Cleaning cooling fins. •Haveorbitingscrollbearingandpincrankbearingsgreased(seenote3). •Replacetipsealsanddustseal. •Replaceinletseal.

Every4years

10000 B 8barand116psicompressors: •Replacetheelementoutletpipeandtheplasticinsert.SeesectionOutletpipereplacement(3.7kWelementsonly). •Cleanfan(ref124onFlowdiagram),fanductandele-ment cooling fins (see note 2). See section Cleaning cooling fins. •Haveorbitingscrollbearingandpincrankbearingsgreased(seenote3). •Replacetipsealsanddustseal. •Replaceinletseal.



Notes:

1. Maintenance must be done according the number of running hours or according the running period, whichever comes first.

2. More frequently in a dusty environment.

3.Important note:Regreasingofthebearingsofthecompressorelementmustbedone with special grease, a special grease gun and according a specific procedure. Inhighambientconditions,thebearingsmustbegreasedmorefrequently:forevery5°C(9°F)increaseabove30°C(86°F),themaintenanceintervalshouldbereducedwith30%. Contact your supplier for details. Checkmorefrequentlyifoperatinginadustyatmosphere.Checkforcleannessanddamage. Replace a dirty or damaged filter by a new one.

4.Inextremelydryconditions(relativehumiditybelow15%),thetipsealsanddustseals need to be replaced more frequently.

Service kitsService kits

Foroverhaulingandforpreventivemaintenance,awiderangeofservicekitsisavailable.Servicekitscompriseallpartsrequiredforservicingthecomponentandofferthebenefitsofgenuinepartswhilekeepingthemaintenancebudgetlow.

ConsulttheSparePartsListforpartnumbers.

Disposal of used materialUsedfiltersoranyotherusedmaterial(e.g.desiccant,lubricants,cleaningrags,machineparts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.

ElectroniccomponentsaresubjecttotheEUDirective2002/96/ECforWasteElectricalandElectronicEquipment(WEEE).Assuch,thesepartsmustnotbedisposedofatamunicipal waste collection point. Refer to local regulations for directions on how to dispose of this product in an environmental friendly manner.

Section VII - Adjustments and servicing procedures


• Air filter• Air cooler• Drive motor• Safety valve• Belt set exchange and tensioning• Cleaning the compressor element• Replacement of the outlet pipe• Dryer maintenance

Air filterProcedure



1. Stop the compressor, close the air outlet valve and switch off the voltage.

2.Removethefiltercover(1)andthefilterelement.Discarddamagedorcloggedelements. Clean the cover.

3.Fitthenewelementandreinstallthefiltercover.

Air coolerCleaning

Keepthecoolercleantomaintaincoolingefficiency.Ifnecessary,removeanydirtwithafibrebrush.Neveruseawirebrushormetalobjects.

Next,cleanbyairjetinreversedirectionofnormalflow.



Drive motorInstructions

Themotorbearingsaregreasedforlifeanddonotrequirespecialattention.

Keepthemotorfreefromdustforoptimalcooling.

Safety valve



Operating

Operatethesafetyvalve(5)byunscrewingtheknurledcaponeortwoturns.Retightenthe cap.

Testing

Thevalvecanbetestedonaseparatecompressedairline.

Ifthesafetyvalvedoesnotopenatthespecifiedpressure,itmustbereplaced.

CAUTION!

No adjustments are allowed. Never run the compressor without safety valve.



Belt set exchange and tensioningImportant

NOTICE!The belts must be replaced as a set, even if only one of them seems worn.

Procedure

1.Loosenmotorhold-downbolts(3).2.Loosenthebelttensionbyscrewingbolts(4)equallyandtakeoffthebelts(1).3.Installnewbelts.4.Tensionthebeltsbyscrewingbolts(4)equally. Thetensioniscorrectifthedeflectionisbetween5mmand7mmwhenexertingaforceof25Nonthebeltmidwaybetweenthepulleys.Makesurethatthepulleysremainaligned.Themaximumout-of-lineis:•Maximumparallelout-of-line:0.5mm•Maximumangularout-of-line:0.5degrees5.Tightenbolts(3).6.Checkthebelttensionafterthefirst500runninghours.

Cleaning the compressor element

CAUTION!

• Compressor element cooling channels can be hot when the compressor has just beenturned off.

• Do not clean the cooling channels with organic solvent since this will damage thesurface treatment.

Thepurposeofcleaningthecoolingchannelsofascrollelementistopreventthecoolingchannelstosiltupandassuchreducethecoolingefficiency.Areducedcoolingefficiency can lead towards a premature compressor element failure.



Procedure:

1. Stop the compressor and switch off the power.2. Close the air outlet valve and depressurise the compressor.3.Removethefanduct:•Unscrewthe3bolts(1).

•Removeclip(2)(ifapplicable).

•Removefanduct(3).

4.Cleancoolingchannels:

•Removedustfromthecoolingchannels(1)bymeansofairjet(seenextfigure).

•Cleanthefanduct(2).

5.Reassemblethefanduct:

•Putthefanductinplace.

•Fitthe3boltsandtheclip.

Theunitisnowagainreadyforuse.



Replacement of the outlet pipe(only applicable to QOF 20)

Description

Thescrollelementoutletpipe(1)containsaplasticinsert(3).Duetotheheatofthecompressedair,theplasticinsertcanbecomebrittle.Thereforeitisrecommendedtoreplacetheoutletpipetogetherwiththeinsertwhenthatisthecase.Bothpartsareavailableasakit(outletpipeset).SeetheSparePartsListforpartnumber.

Theoutletpipesetcontainstwoparts:

•Theplasticinsert(3)

•Themetaloutletpipe(1)

Procedure

1.Stopthecompressor,depressurizeandswitchoffthevoltage.

2.Loosenthecoupling(3)whilefixatingthenipple(2)withaspanner.

3.Removetheoutletpipetogetherwiththenipple

4.Fitthenippletothenewoutletpipeandtighten.UseonlyPTFEtape.

5.Fittheplasticinsertinplaceasindicatedonthedrawingandassembletheoutletpipewithamaximumtorqueof10Nm(7.4lbf.ft)plusmaximumoneturn(360°). Warning:Iftheoutletpipeistightenedtoohard,theinsertcanbreak,resultinginoverheating of the compressor element.



Dryer maintenance(only applicable to compressors with refrigerant dryer)

Safety precautions

Thedryercircuitcontainsrefrigerant.When handling refrigerant, all applicable Safety precautions during maintenance or repair must be observed. Specifically be aware of following points:

•Contactofliquidrefrigerantwiththeskincancausefreezing.Wearspecialgloves.Ifcontactedwiththeskin,theskinshouldberinsedwithwater.Onnoaccountmayclothing be removed.

•Fluidrefrigerantcanalsocausefreezingoftheeyes.Wearsafetyglasses.

•Avoidinhalationofrefrigerantvapors.Checkthattheworkingareaisadequatelyventilated.

Beawarethatinternalcomponentsofthedryersuchasthepipescanreachatemperatureofupto110˚C(230˚F).Therefore,waituntilthedryerhascooleddownbefore removing the side panels.

Beforestartinganymaintenanceorrepairwork,switchoffthevoltageandclosetheairoutlet valve.

Local legislation may stipulate that:

•Workontherefrigerantcircuitofthecoolingdryeroronanyequipmentwhichinfluencesitsfunctionmustbeundertakenbyanauthorizedcontrolbody.

•Theinstallationshouldbecheckedonceayearbyanauthorizedcontrolbody.

General

Thefollowingremarksshouldbekeptinmind:

•Keepthedryerclean.

•Brushorblowoffthefinnedsurfaceofcondenserregularly.

Device settings

Theregulatingandsafetydevicesarefactoryadjustedtoobtainoptimumperformanceofthedryer.Donotalterthesettingofanyofthedevices.

CAUTION!

Connecting pressure measuring devices in the refrigerant circuit can change the amount of refrigerant in the system. This results in a less optimal working of the dryer.

Section VIII - Problem solving


NOTICE!Before carrying out any maintenance or repair, perform following steps:

• Stop the compressor and switch off the voltage.• Open and lock the isolating switch to prevent an accidental start.• Isolate the compressor by closing the outlet valve.• Depressurize the system by opening the drain valve(s).

Compressor

Condition Fault Remedy

Thecompressordoes not start.

Pressuretoohigh.Compressor will start again when the pressure drops to the starting pressure.

Loose connection. Checkallelectricalconnections.

Safety valve blows.Pressuretoohigh Checksettingsandcorrect.

Safety valve opens too soon. Replace valve.

Compressor capacity or pressure below normal.

Airconsumptionexceedscapacity of compressor. Checkequipmentconnected.

Chokedairinletfilter. Removeandcheckfilter.Replaceif necessary.

Safetyvalveleaking. Replace valve.

Compressor element out of order. Consult your supplier.

Compressor module overheating or compressor shutdown on high air temperature.

Insufficientcompressorcooling.

Improveventilationofcompressor room. Clean compressor element fins and fan, see Cleaning the compressor element.

Cooling fan out of order. Checkandcorrect.

Condensate trap continuously discharging air an water

Automaticdrainoutoforder Havethedrainchecked.Replaceas necessary

Refrigerant dryer

Forcompressorswithabuilt-inrefrigerantdryeralso:

Section VIII - Problem solving


Condition Fault Remedy

Dewpointtoohigh

AirinlettemperaturetoohighCheckandcorrect;seesectionReference conditions and limitations

Fusesblown Checkfusesandremedythecause.

Shortage of refrigerant Have circuit repaired or recharged.

Refrigerant compressor does not run See below

Evaporatorpressureistoohigh See below

Condenser pressure is too high See below

Condenser pressure too high or too low

Fancontrolswitchoutoforder Have switch replaced

Condenser fan motor out of order Have fan motor inspected

AmbienttemperaturetoohighImproveventilationofcompressor room, see section Installationproposal

Condenser externally clogged Clean condenser

Motor of refrigerant compressor stops or does not start

Theinternalthermalprotectionof the motor has tripped

Compressor will restart when the motor windings have cooled down.

Electricpowersupplytorefrigerant compressor interrupted

Checkandcorrectasnecessary

Evaporatorpressure is too high or too low

Condenser pressure too high or too low See above

Shortage of refrigerant Have circuit repaired or recharged

Hot gas bypass valve incorrectly set or out of order

Have the valve adjusted or replaced

Condensate trap continuously discharging air an water

Automaticdrainoutoforder Havethedrainchecked.Replaceas necessary

Electroniccondensate drain inoperative

Drainsystemclogged

Clean the filter of the automatic drain by opening the manual drainvalve.Checkfunctioningof the drain by pushing the test button.



• Electric cable size and fuses• Reference conditions and limitations• Compressor data

Electric cable size and fuses Notice!

• The voltage on the compressor terminals must not deviate more than 10% of thenominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).• If cables are grouped together with other power cables, it may be necessary to usecables of a larger size than those calculated for the standard operating conditions.• Use the original cable entry, indicated on the dimension drawings.To preserve the IP protection degree of the electric cubicle and to protect its components from dust from the environment, it is mandatory to use a proper cable gland when connecting the supply cable to the compressor.• Local regulations remain applicable if they are stricter than the values proposed below.. • Caution:• Always double-check the fuse size versus the calculated cable size. If required,

reduce fuse size or enlarge cable size.• Cable length should not exceed the maximum length according to IEC 60204 table

10.Currents and fuses

Compressor type Itot(1)

Max fuse (1)

Itot(2)Max fuse (2)

Q21/Q22/Q23/Q24

Q15

QOF20 IEC 50Hz 230V 55A 63A 60A 80A 15.0A

QOF20 IEC 60Hz 380V 32A 40A 37A 50A 8.9A

QOF20 IEC 50Hz 400V 32A 35A 35A 50A 8.7A

QOF20 IEC 50Hz 400V+N 32A 35A 37A 50A 8.7A

QOF20 UL/cUL 60Hz 200V 60A 70A 68A 80A 16.6A






Compre-ssor type

Itot(1) Max fuse (1) Itot(2)

Max fuse (2)

Q21/Q22/Q23/Q24

Q15

QOF22 IEC 50Hz 230V 64A 80A 69A 80A 23.3A 0.38A



QOF22 IEC 50Hz 400V+N 37A 50A 44A 50A 13.4A 0.22A

QOF22 UL/cUL 60Hz 200V 76A 90A 84A 100A 25.0A 0.74A




Compre-ssor type

Itot(1) Max fuse (1) Itot(2)

Max fuse (2)

Q21/Q22/Q23/Q24

Q15




QOF30 IEC 50Hz 400V+N 49A 63A 58A 63A 13.4A 0.22A





Itot(1):maximumcurrentinthesupplylinesatmaximumloadandnominalvoltageforcompressors without integrated dryer.

Maxfuse(1):maximumfusesizeincaseofcompressorswithoutintegrateddryer.

Itot(2):maximumcurrentinthesupplylinesatmaximumloadandnominalvoltageforcompressors with integrated dryer.

Maxfuse(2):maximumfusesizeincaseofcompressorswithintegrateddryer.

IECfuses:classgL/gG

ULfuses:classK5;CSA:HRCformII



Possible configurations

Thereare3possiblecablinglayouts:

•(1):Singlesupplycables(forDOLvariants,onlyK21isused)•(2):Parallelsupplycables(forDOLvariants,onlyK21isused)•(3)isonlyvalidforY-Dversions

Cable sizing according IEC

Thetablesbelowindicatethecurrentcarryingcapacitiesofcablesfor3commonlyusedinstallationmethods,calculatedaccordingtostandard60364-5-52-electricalinstallationsofbuildingspart5-selectionanderectionequipmentandsection52-current carrying capacities in wiring systems.

TheallowedcurrentsarevalidforPVCinsulatedcableswiththreeloadedcopperconductors(maximumconductortemperature70°C).

InstallationmethodB2accordingtableB.52.1.

Multicore cable in conduit on a wooden wall

Maximum allowed current in function of the ambient temperature for installation method B2

Ambient temperature

Cable section 30°C 40°C 45°C 50°C 55°C

4mm² <27A <23A <21A <19A <16A

6mm² <34A <30A <27A <24A <21A

10mm² <46A <40A <36A <33A <28A

16mm² <62A <54A <49A <44A <38A

25mm² <80A <70A <63A <57A <49A

35mm² <99A <86A <78A <70A <60A

50mm² <118A <103A <93A <84A <72A

70mm² <149A <130A <118A <106A <91A

95mm² <179A <156A <141A <127A <109A

120mm² <206A <179A <163A <146A <126A



InstallationmethodCaccordingtableB.52.1.

Single core or multicore cable on a wooden wall

Maximum allowed current in function of the ambient temperature for installation method C

Ambient temperature


4mm² <32A <28A <25A <23A <20A

6mm² <41A <36A <32A <29A <25A

10mm² <57A <50A <45A <40A <35A

16mm² <76A <66A <60A <54A <46A

25mm² <96A <84A <76A <68A <59A

35mm² <119A <104A <94A <84A <73A

50mm² <144A <125A <114A <102A <88A

70mm² <184A <160A <145A <131A <112A

95mm² <223A <194A <176A <158A <136A

120mm² <259A <225A <205A <184A <158A

InstallationmethodFaccordingtableB.52.1.

Single-corecables,touchinginfreeair

Clearance to wall not less than one cable diameter

Maximum allowed current in function of the ambient temperature for installation method F

Ambient temperature


25mm² <110A <96A <87A <78A <67A

35mm² <137A <119A <108A <97A <84A

50mm² <167A <145A <132A <119A <102A

70mm² <216A <188A <171A <153A <132A

95mm² <264A <230A <209A <187A <161A

120mm² <308A <268A <243A <219A <188A

Calculation method for IEC:

•Singlesupplycables(3phases+PE-configuration(1)):

•Add10%tothetotalcurrent(Itotfromthetables)



•Installtheprescribedfuseoneachcable•Parallelsupplycable(2x3phases+PE-configuration(2)):

•Add10%tothetotalcurrent(Itotfromthetables)anddivideby2•Multiplytheampacityofthecableswith0.8(seetableA.52.17(52-E1))•Installfusesofhalfthesizeoftherecommendedmaximumfusesizeoneachcable.•Whenusing2x3phases+PEasin(3):

•Add10%tothetotalcurrent(Itotfromthetables)anddivideby√3•Multiplytheampacityofthecableswith0.8(seetableA.52.17(52-E1))•Fusesize:therecommendedmaximumfusesizedividedby√3oneachcable.•SizeofthePEcable:usefollowingruleofthumb:

•Forsupplycablesupto16mm²:samesizeassupplywires•Forsupplycablesbetween16mm²and35mm²:16mm²•Forsupplycableslargerthan35mm²:halfthesizeofthesupplywires

Alwayscheckthevoltagedropoverthecable(lessthan5%ofthenominalvoltageisrecommended)!Example:ForQOF15T400V50HzIEC,Itot=52A,ambienttemperatureis40°C,recommendedfuse:maximum63A.•Incaseofsinglesupplycables(3phases+PE-configuration(1)):

•I=52A+10%=52x1.1=57.2A

•ThetableforinstallationmethodB2allowsamaximumcurrentof54Afora16mm²cable.Foracableof25mm²,themaximumallowedcurrentis70A,whichissufficient.Therefore,usea3x25mm²+16mm²cable. IfmethodCisused,16mm²issufficient(maximum66Aat40°C).Usea3x16+16mm²cable.

•Install63Afuses.

•Incaseofparallelsupplycables(2x3phases+PE-configuration(2)):

•I=(52A+10%)/2=(52x1.1)/2=28.6A•Foracableof6mm²andinstallationmethodB2,themaximumcurrentis30Ax

0.8=24A,whichisinsufficient.Foracableof10mm²,themaximumallowedcurrentis50Ax0.8=40A.So2parallelcablesof3x10mm²+10mm²aresufficient. IncaseofinstallationmethodC,themaximumcurrentofa6mm²cableat40°Cis36Ax0.8=28.8 A.2parallelcablesof3x6+6mm²willbesufficient.

•Install32Afusesoneachcable..

Cable sizing according UL/cUL

CalculationmethodaccordingUL508A,table28.1column5:allowableampacitiesofinsulatedcopperconductors(75°C(167°F)).

Maximumallowedcurrentinfunctionofthewiresize(NFPA70table310.16)

AWGorkcmil Maximum current

14 20A

12 25A

10 35A



8 50A

6 65A

4 85A

3 100A

2 115A

1 130A

Correction factors

Ambienttemperature Correction factor

21-25°C(70-77°F) 1.05

26-30°C(78-86°F) 1.00

31-35°C(87-95°F) 0.94

36-40°C(96-104°F) 0.88

Calculation method for UL:

•Singlesupplycables(3phases+1PE-configuration(1)):

•Add25%tothetotalcurrent(Itotfromthetables)(seeUL508A28.3.2:“Ampacityshallhave125%ofthefullloadcurrent”).

•Installtheprescribedmaximumfuseoneachcable

•Parallelsupplycable(2x3phases+2PE-configuration(2)):

•Add25%tothetotalcurrent(Itotfromthetables)anddivideby2

•Multiplytheampacityofthecableswith0.8(seeUL508Atable28.1continued)

•Installfusesofhalfthesizeoftherecommendedmaximumfusesizeoneachcable.

•Whenusing2x3phase+2PEasin(3):

•Add25%tothetotalcurrent(Itotfromthetables)anddivideby√3

•Multiplytheampacityofthecableswith0.8(seeUL508Atable28.1continued)

•Fusesize:therecommendedmaximumfusesizedividedby√3oneachcable.

•SizePEcable:

•ForsupplycablesuptoAWG8:samesizeasthesupplycables

•ForsupplycableslargerthanAWG8:usemaximumallowedampacityoftheselectedsupplycablesandcomparewithvalueintablebelow(seeCECPart1table17)

<100A:useAWG8

<200A:useAWG6

<300A:useAWG4

Alwayscheckthevoltagedropoverthecable(lessthan5%ofthenominalvoltageisrecommended).

Exampleofsupplycablecalculation:Itot=28A,maximumambienttemperatureis40°C,recommendedfuse=40•Singlesupplycables(3phases+1PE-configuration(1)):

•I=28A+25%=28x1.25=35A



•ForAWG8,themaximumcurrentat40°Cis50Ax0.88=44A,whichissufficient=>useAWG8.

•Installtheprescribedmaximumfuse(40A)oneachcable

•Parallelsupplycable(2x3phases+2PE-configuration(2)):

•I=(28A+25%)/2=(28x1.25)/2=17.5A

•ForaAWG14,themaximumcurrentat40°Cis20Ax0.88x0.8=14.1A,whichisinsufficient.ForanAWG14,themaximumcurrentis25x0.88x0.8=17.6A.So2parallelcablesof3xAWG12+2xAWG12aresufficient.

•Install20Afusesoneachcable..

Reference conditions and limitationsReference conditions

Airinletpressure(absolute) bar 1

Airinletpressure(absolute) psi 14.5

Airinlettemperature ºC 20

Airinlettemperature ºF 68

Relative humidity % 0

Workingpressure See section Compressor data

Limits

Maximumworkingpressure See section Compressor data

Maximum inlet temperature ºC 40

Maximum inlet temperature ºF 104

Minimum ambient temperature ºC 0

Minimum ambient temperature ºF 32



Compressor data Notice!

All data specified below apply under reference conditions, see section Reference conditions and limitations.

8 bar compressors, 50 Hz

Compressor type QOF 20 QOF 22 QOF 30

Maximumworkingpressure(compressorswithout integrated dryer) bar(e) 8 8 8

Maximumworkingpressure(compressorswithout integrated dryer) psi(g) 116 116 116

Maximumworkingpressure(compressorswithintegrated dryer) bar(e) 7.75 7.75 7.75

Maximumworkingpressure(compressorswithintegrated dryer) psi(g) 112 112 112

Referenceworkingpressure(compressorswithout integrated dryer) bar(e) 7 7 7

Referenceworkingpressure(compressorswithout integrated dryer) psi(g) 101.5 101.5 101.5

Referenceworkingpressure(compressorswithintegrated dryer) bar(e) 6.75 6.75 6.75

Referenceworkingpressure(compressorswithintegrated dryer) psi(g) 98 98 98

Airtemperatureatoutletvalve(compressorswithout integrated dryer) °C 32 30 30

Airtemperatureatoutletvalve(compressorswithout integrated dryer) °F 90 86 86

Airtemperatureatoutletvalve(compressorswith integrated dryer) °C 25 25 20

Airtemperatureatoutletvalve(compressorswith integrated dryer) °F 77 77 68

Motor shaft speed rpm 2900 2900 2900

Nominalmotorpower kW 4x3.7 3x5.5 4x5.5

Nominalmotorpower hp 4x5 3x7.5 4x7.5

Sound pressure level (compressors without integrated dryer) dB(A) 63 64 65

Refrigerant type (compressors with integrated dryer) °C R404a R404a R404a

Dewpoint(compressorswithintegrateddryer) °F 4 4 4




10 bar compressors, 50 Hz


















Refrigerant type (compressors with integrated dryer) R404a R404a R404a

Dewpoint(compressorswithintegrateddryer) °C 4 4 4


116 psi compressors, 60 Hz
























145 psi compressors, 60 Hz









Section X - Guidelines for inspection


Guidelines

OntheDeclarationofConformity/DeclarationbytheManufacturer,theharmonisedand/or other standards that have been used for the design are shown and/or referred to.

TheDeclarationofConformity/DeclarationbytheManufacturerispartofthedocumentation that is supplied with this compressor.

Local legal requirements and/or use outside the limits and/or conditions as specified by the manufacturer may require other inspection periods as mentioned below.

Section XI - PED (Pressure Equipment Directive)


Components subject to 97/23/EC Pressure Equipment Directive

Componentssubjectto97/23/ECPressureEquipmentDirectivegreaterthanorequaltocategoryII:

Part number Description Medium Pressure

0830100917 Safety valve Air 9.3bar



0830100835 Safety valve Air 11 bar

Volume P x V or P Life cycle PED class

NA NA 2x106 IV

NA NA 2x106 IV

NA NA 2x106 IV

NA NA 2x106 IV

Overall rating

ThecompressorsconformtoPEDcategoryIorsmaller.

Section XII - Declaration of conformity


Typical example of a Declaration of Conformity document

(1):Contactaddress:InternationalCompressorDistributionNVBoomsesteenweg957B-2610Wilrijk(Antwerp)Belgium

Section XII - Declaration of conformity


OntheDeclarationofConformity/DeclarationbytheManufacturer,theharmonizedand/or other standards that have been used for the design are shown and/or referred to.TheDeclarationofConformity/DeclarationbytheManufacturerispartofthedocumentation that is supplied with this device.

Standard termS and ConditionS

QuinCy CompreSSor and ortman Fluid power diviSionS

TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyer’s default, have the right to repossess such equipment.

PATENT INFRINGEMENT: If properly notified and given an opportunity to do so with friendly assistance, Seller will defend Buyer and the ultimate user of the equipment from any actual or alleged infringement of any published United States patent by the equipment or any part thereof furnished pursuant hereto (other than parts of special design, construction, or manufacture specified by and originating with Buyer), and will pay all damages and costs awarded by competent court in any suit thus defended or of which it may have had notice and opportunity to defend as aforesaid.

STANDARD WARRANTY: Seller warrants that products of its own manufacture will be free from defects in workmanship and materials under normal use and service for the period specified in the product instruction manual. Warranty for service parts will be ninety (90) days from date of factory shipment. Electric Motors, gasoline and diesel engines, electrical apparatus and all other accessories, components and parts not manufactured by Seller are warranted only to the extent of the original manufacturer’s warranty.

Notice of the alleged defect must be given to the Seller, in writing with all identifying details including serial number, type of equipment and date of purchase within thirty (30) days of the discovery of the same during the warranty period.

Seller’s sole obligation on this warranty shall be, at its option, to repair or replace or refund the purchase price of any product or part thereof which proves to be defective. If requested by Seller, such product or part thereof must be promptly returned to seller, freight prepaid, for inspection.

Seller warrants repaired or replaced parts of its own manufacture against defects in materials and workmanship under normal use and service for ninety (90) days or for the remainder of the warranty on the product being repaired.

This warranty shall not apply and Seller shall not be responsible or liable for:

(a) Consequential, collateral or special losses or damages;

(b) Equipment conditions caused by fair wear and tear, abnormal conditions of use, accident, neglect or misuse of equipment, improper storage or damage resulting during shipping;

(c) Deviation from operating instructions, specifications or other special terms of sale;

(d) Labor charges, loss or damage resulting from improper operation, maintenance or repairs made by person(s) other than Seller or Seller’s authorized service station.

In no event shall Seller be liable for any claims whether arising from breach of contract or warranty or claims of negligence or negligent manufacture in excess of the purchase price.

THIS WARRANTY IS THE SOLE WARRANTY OF SELLERS AND ANY OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE ARE HEREBY SPECIFICALLY EXCLUDED.

LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability for liquidated damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of construction, whether resulting from delays in delivery or performance, breach of warranty, negligent manufacture or otherwise.

ENVIRONMENTAL AND OSHA REQUIREMENTS: At the time of shipment of the equipment from the factory, Quincy Compressor / Ortman Fluid Power will comply with the various Federal, State and local laws and regulations concerning occupational health and safety and pollution. However, in the installation and operation of the equipment and other matters over which the seller has no control, the Seller assumes no responsibility for compliance with those laws and regulations, whether by the way of indemnity, warranty or otherwise.


Standard termS and ConditionS

QuinCy CompreSSor and ortman Fluid power diviSionS

LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyer’s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order.

The rights of Buyer hereunder shall be neither assignable nor transferable except with the written consent of Seller.

This order may not be canceled or altered except with the written consent of Seller and upon terms which will indemnify Seller against all loss occasioned thereby. All additional costs incurred by Seller due to changes in design or specifications, modification of this order or revision of product must be paid for by Buyer.

In addition to the rights and remedies conferred upon Seller by this order, Seller shall have all rights and remedies conferred at law and in equity and shall not be required to proceed with the performance of this order if Buyer is in default in the performance of such order or of any other contract or order with seller.

TERMS OF PAYMENT: Unless otherwise specified in the order acknowledgment, the terms of payment shall be net cash within thirty (30) days after shipment. These terms shall apply to partial as well as complete shipments. If any proceeding be initiated by or against Buyer under any bankruptcy or insolvency law, or in the judgment of Seller the financial condition of Buyer, at the time the equipment is ready for shipment, does not justify the terms of payment specified, Seller reserves the right to require full payment in cash prior to making shipment. If such payment is not received within fifteen (15) days after notification of readiness for shipment, Seller may cancel the order as to any unshipped item and require payment of its reasonable cancellation charges.

If Buyer delays shipment, payments based on date of shipment shall become due as of the date when ready for shipment. If Buyer delays completion of manufacture, Seller may elect to require payment according to percentage of completion. Equipment held for Buyer shall be at Buyer’s risk and storage charges may be applied at the discretion of Seller.

Accounts past due shall bear interest at the highest rate lawful to contract for but if there is no limit set by law, such interest shall be eighteen percent (18%). Buyer shall pay all cost and expenses, including reasonable attorney’s fees, incurred in collecting the same, and no claim, except claims within Seller’s warranty of material or workmanship, as stated below, will be recognized unless delivered in writing to Seller within thirty (30) days after date of shipment.

TAXES: All prices exclude present and future sales, use, occupation, license, excise, and other taxes in respect of manufacture, sales or delivery, all of which shall be paid by Buyer unless included in the purchase price at the proper rate or a proper exemption certificate is furnished.

ACCEPTANCE: All offers to purchase, quotations and contracts of sales are subject to final acceptance by an authorized representative at Seller’s plant.

DELIVERY: Except as otherwise specified in this quotation, delivery will be F. O. B. point of shipment. In the absence of exact shipping instruction, Seller will use its discretion regarding best means of insured shipment. No liability will be accepted by Seller for so doing. All transportation charges are at Buyer’s expense. Time of delivery is an estimate only and is based upon the receipt of all information and necessary approvals. The shipping schedule shall not be construed to limit seller in making commitments for materials or in fabricating articles under this order in accordance with Seller’s normal and reasonable production schedules.

Seller shall in no event be liable for delays caused by fires, acts of God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any kind beyond Seller’s control. No provision for liquidated damages for any cause shall apply under this order. Buyer shall accept delivery within thirty (30) days after receipt of notification of readiness for shipment. Claims for shortages will be deemed to have been waived if not made in writing within ten (10) days after the receipt of the material in respect of which any such shortage is claimed. Seller is not responsible for loss or damage in transit after having received “In Good Order” receipt from the carrier. All claims for loss or damage in transit should be made to the carrier.


Notes

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OIL-FREE SCROLL COMPRESSORS - Air Compressors Direct€¦ · QOF 20, QOF 22 and QOF 30 are...

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