BeaconMedaes 4107 9006 25, Installation, Operation And Maintenance Instructions

Page 1: ...Installation Operation and Maintenance Instructions Scroll Laboratory Air Compressor System 10 C Dew Point Part number 4107 9006 25 Revision 11 September 15 2020...

Page 2: ...purchased Model number Serial number Option s included Any information service or spare parts requests should include the machine serial number and be directed to BeaconMed s 1059 Paragon Way Rock Hi...

Page 3: ...hutdown Alarms 4 0 Trouble Shooting 5 0 Maintenance 5 1 Maintenance Schedule 5 2 Service Kits 6 0 Inspection Replacement Procedures 6 1 V Belts 6 2 Air Intake Filter 6 3 Motor Lubrication 6 4 Liquid L...

Page 4: ...int Transmitter B 1 General Information B 2 Introduction B 3 Speci cations B 4 Operation B 5 Alarms B 6 Maintenance B 7 Troubleshooting B 8 Dew Point Sensor Calibration B 9 Dew Point Sensor Replacemen...

Page 5: ...or other devices Notify appropriate hospital personnel if repairs or maintenance will affect available compressed air levels This is a high speed rotating piece of machinery Do not attempt to service...

Page 6: ...compressor is v belt driven and protected by an OSHA approved totally enclosed beltguard A sliding motor mounting base that is fully adjustable with two adjusting screws is incorporated to achieve bel...

Page 7: ...alarm are included Final Line Filters and Regulators Fully duplexed nal line lters rated for 1 micron with element change indicators along with duplexed nal line regulators are factory mounted and pip...

Page 8: ...rtable and mobile RF communications equipment can affect Medical Electrical Equipment The use of accessories transducers and cables other than those speci ed by the manufacturer may result in decrease...

Page 9: ...mmercial or hospital environment Surge IEC 61000 4 5 1 kV differential mode 2 kV common mode 1 kV differential mode 2 kV common mode Mains power quality should be that of a typical commercial or hospi...

Page 10: ...stance in metres m Field strengths from xed RF transmitters as determined by an electromagnetic site survey a should be less than the compliance level in each frequency range b Interference may occur...

Page 11: ...If the system must be separated carefully label all electrical connections that are removed for easier re assembling at the nal destination Place units to ensure high visibility of indicators and gau...

Page 12: ...ssure drop tables Total pressure drop in piping should not exceed 5 psi 2 6 Wiring WARNING BESURETODISCONNECTALLELECTRICAL POWER FROM THE COMPRESSOR BEFORE PERFORMING ANY ELECTRICAL PROCEDURES Refer t...

Page 13: ...tional holes in the control panel as this may void the system warranty See Figure 2 1 for opening locations Ensure that the emergency generation system electrical supply is consistent with the air sys...

Page 14: ...installation to ensure they are tight Check the air receiver dryers controls and compressors for damage Check the drain valves on the air receiver and compressor modules Check all valves for full open...

Page 15: ...be locked out NOTE DO NOT ADD OIL TO THE COMPRESSOR The design of the Scroll compressor is totally oil less It is not necessary to ll the crankcases with oil Inside the control panel make sure that al...

Page 16: ...r correct direction of rotation of each compressor by pressing the Rotation button on touchscreen display found in the Service section of the Unit touchscreens See Section D 3 7 for additional informa...

Page 17: ...the dryer pressures appear as expected open the dryer lter regulator outlet isolation valve Close the other dryer lter regulator inlet and outlet isolation valves CAUTION Only one dryer lter regulato...

Page 18: ...the lead compressor to start at 130 psig with falling system pressure If the one compressor can carry the load then the system pressure will rise to 140 psig At this point the control will turn off th...

Page 19: ...ing will come to line pressure There is a 5 second repressurization cycle If the dryer is in the Manual mode the dryer will use 15 of the system capacity to purge the dryer When the dryer is in the Au...

Page 20: ...e Alarm This will not shut down the compressor in question but instead is a warning that a shutdown is likely to occur The condition should be checked immediately see High temperature alarm in the Tro...

Page 21: ...hort time delay 1 5 seconds is started when both pressure switches fall below 50 psig to eliminate false alarms during normal tower switching To eliminate alarms during periods when the dryer is turne...

Page 22: ...sor Loose or faulty connection Check tighten all wire connections Power failure Main fuse blown Replace fuse Fuse blown in control circuit Replace fuse Compressor shuts off unexpectedly Overload tripp...

Page 23: ...ten System undersized Contact BeaconMed s Faulty pressure sensor Replace sensor System piping leaks Repair leaks Check valve or line to receiver is leaking or plugged Replace if necessary Both dryers...

Page 24: ...nsor accuracy Yearly Verify dew point sensor accuracy contact BeaconMed s Replace compressor inlet lters v belts and dryer pre lters after lters Yearly Purchase 1 Year System Basic Service Kit Purchas...

Page 25: ...Size A 1 2 Dryer inlet lters 2 Dryer discharge lters 2 Inlet lter oat drains 2 Purge mufflers 1 Sight glass tube 1 3 8 Polyproplyene ball 1 3 8 In line check valve 1 1 2 MNPT inline lter 90 micron sig...

Page 26: ...ove 1 Year Unit 10 BAR Basic Service Kits 1 Unit Kit is required for each compressor unit For Systems with Piped Inlet KIT NUMBER WHERE USED DESCRIPTION QTY CONTENTS 4107 4003 29 2 Hp 60 Hz 2 Hp Scrol...

Page 27: ...6 lb bags desiccant 2 ISO4 dryer service kit Note Each dryer service kit contains 2 O Rings for canister bases 2 O Rings for tower mounting anges 2 check valves for dryer manifold block and 2 O Rings...

Page 28: ...earings 3 In high ambient conditions the bearings must be greased more frequently for every 9 F increase above 86 F the maintenance interval should be reduced by 30 5 2 7 2 3 Hp Only 10 000 Hours or E...

Page 29: ...ls Cleaning of the parts guiding the cooling air and replacement of the tipseals should be performed during every service interval 5 2 9 7 5 15 Hp Only Service Intervals PART KIT NUMBER QTY ACTION AT...

Page 30: ...agm 1 Anchor Plate 2 Springs 3 O rings 4107 4017 85 Zero Loss Drain Valve Service Kit for UFM D05 included in System Basic Service Kit 1 Systems with UFM D05 Drain 1 UFM D05 Drain Valve Service Module...

Page 31: ...19 2 1 4 6 5 10 4107 6544 20 4 9 32 6 5 15 4107 6505 47 4 9 32 6 5 WARNING Before starting any maintenance procedures disconnect all power to the package Never perform any maintenance functions while...

Page 32: ...se until the proper tension and alignment is obtained To check for correct alignment place a straight edge on the faces of the two sheaves Proper alignment is obtained when all the gaps between the st...

Page 33: ...The air intake lter element should be changed annually under normal operating conditions To change the lter 1 Turn off the compressor being serviced and lock open the appropriate disconnect switches...

Page 34: ...4 Figure 6 4 Sight Glass 6 3 Motor Lubrication 6 3 1 Lubrication Information This a ball or roller bearing motor The bearings have been lubricated at the factory Motors are pregreased New motors that...

Page 35: ...n sight glass 2 Top knob on manual drain sight glass 3 Receiver drain valve 6 5 2 Recommended Maintenance Visual check and function verification Inspect the condensate drain for external damages and l...

Page 36: ...tronic material Mechanical stresses including moderate ones can give rise to irreparable malfunctions Insert the new O Ring of the filter cap place the new filter on the cap and close on the valve ass...

Page 37: ...2 Electronic board 03 Solenoid valve 04 Filter cap 1 05 Filter cap O Ring 1 06 Double mesh metallic filter 1 07 Valve assembly O Ring 1 08 Solenoid valve spring 1 09 Solenoid valve pilot 1 10 Diaphrag...

Page 38: ...resetting cyclepressure switch and make fine adjustments be repeating steps 2 through 4 trial and error process until the desired setting is obtained 6 Slide the adjustment access cover back into plac...

Page 39: ...ed to BeaconMed s 1800 Overview Drive Rock Hill SC 29730 Telephone 888 4 MEDGAS 888 463 3427 Fax 803 817 5750 A Parts List is available as a supplement to this Operation and Maintenance Manual Please...

Page 40: ...ons inches Length 47 50 47 50 47 50 47 50 66 00 66 00 Width 34 50 34 50 34 50 34 50 62 00 62 00 Height 74 00 74 00 74 00 74 00 85 10 85 10 Weight lbs 1134 1143 1212 1330 2288 2400 8 2 Triplex Base Mou...

Page 41: ...72 00 Width 62 00 62 00 99 50 99 50 Height 85 10 85 10 85 10 85 10 Weight lbs 2432 2602 3654 3966 8 4 Pentaplex Hexaplex Base Mount Scroll SPC Laboratory Air System Pentaplex Hexaplex Model Hp 10 15...

Page 42: ...Oil Less Scroll Laboratory Air 4107 9006 25 11 Model Number Serial Number Installation Date Date of Service Hours Load Ambient Temp Inlet Filter Belt Tension Misc Serviced By Notes 9 0 Maintenance Rec...

Page 43: ...Oil Less Scroll Laboratory Air 4107 9006 25 11 9 0 Maintenance Record Model Number Serial Number Installation Date Date of Service Hours Load Ambient Temp Inlet Filter Belt Tension Misc Serviced By No...

Page 44: ...n line in a drying cycle throughout normal dryer operation The opposite off line tower is in a regeneration cycle for removal of the previously adsorbed moisture content or in a purge saving cycle at...

Page 45: ...s and retest NOTE Any small leaks on the dryer outlet side will cause a deterioration of the dew point 12 Press Automatic on the dryer display screen to begin operation in Automatic mode 13 On the com...

Page 46: ...or repair work is conducted WARNING Ensure that the dryer and associated pre lter s and after lter s are valve isolated and fully depressurized before attempting to remove or disassemble any subassemb...

Page 47: ...for blockage Clean and replace as required Excessive system ow rate Reduce inlet ow rate and or increase operating pressure Inlet air temperature is above the dryer s design inlet working temperature...

Page 48: ...onent leaks at dryer outlet manifold or downstream of dryer outlet Soap test the dryer outlet manifold and piping downstream of dryer Repair all leaks noted Back pressure on a desiccant chamber during...

Page 49: ...1 for correct system size and part numbers A 4 1 Maintenance Interval Service Interval Description Every year Pre lter Every year After lter Every year Purge muffler Every 3 years Desiccant Every 3 y...

Page 50: ...6 7 8 5 9 10 11 Item Number Description 1 Dryer Inlet 2 Tower Pressure Gauge 3 Dryer Pre Filter 4 Check Valve 2 5 Purge Muffler 6 Poppit Purge Valve 7 441 Switching Valve 8 Dryer After Filter 9 Air S...

Page 51: ...ectrical power to the dryer WARNING Desiccant towers contain springs which may release potential energy upon dismantle 2 Remove hex nuts washers and towers from manifold assembly 3 Remove spring and p...

Page 52: ...minimum 125 psig maximum Maximum Inlet Air Temperature 43 C 110 F Ambient Temperature 4 4 C 40 F minimum 40 5 C 105 F maximum Pressure Dew Point Capability 100 psig 12 C 10 F Normal DP Operating Rang...

Page 53: ...educe the possibility of high dew point in the Laboratory Air line If the dew point transmitter owmeter becomes clogged dew point readings may be inaccurate allowing moisture to accumulate undetected...

Page 54: ...full reliability have all maintenance and testing done by a quali ed technician If this cannot be done maintenance and testing of those parts discussed in this manual may be undertaken by a competent...

Page 55: ...until it reduces to atmospheric pressure 3 Disconnect sensor cable and remove transmitter from piping NOTE Remote alarms will be activated Problem Possible Cause Solution Slow system response Insuffic...

Page 56: ...vering the probe with your hand The dew point reading should rise rapidly If the dew point does not rise or is slow to respond it is time to replace the sensor To replace disconnect the power to the i...

Page 57: ...ty Sensor Unit Screen 2 Unit Screen 1 Alarm Buzzer Power ON Light Figure C 2 Duplex Medical Air Con guration Printed Circuit Boards PCB2 Unit Display PCB4 Dryer PCB1 Main Display PCB2 Unit Display PCB...

Page 58: ...for the Main 5 7 display PCB2 4 One for each of the Unit 3 5 displays PCB3 1 Master Controller PCB4 6 One for each compressor 4 and one for each dryer 2 Appendix C TotalAlert Embedded Control System...

Page 59: ...gure C 4 and is available on most screens Figure C 4 5 7 Screen Toolbar From left to right the toolbar icons represent the following Main Screen default If No Dryers Image is 2x wide and Dryer Image i...

Page 60: ...60 minutes 240 data points 0 25 min resolution 4 hours 240 data points 1 min resolution 24 hours 240 data points 6 min resolution and 6 days 240 data points 0 6 hour resolution If the connecting board...

Page 61: ...dicate the dryer is purging Once the purge cycle is complete and the dryer is ready to switch based on dewpoint in automatic mode the blue arrows are not visible C 2 7 5 7 Service Screen Figure C 9 Se...

Page 62: ...shows as the System maintenance Items that are suggested are shown as a grey button and indicators are not visible or agged for these items When the user resets the timer the action is logged in the...

Page 63: ...tched at the individual unit screen and reset at that screen The system reset button will reset all system shutdown events for that given system not Unit X Green shutdown condition indicates a normal...

Page 64: ...e miscellaneous general information to be displayed and changed C 3 PCB2 3 5 Display Controller C 3 1 Basic Software Architecture The primary purpose of PCB2 is to drive the LCD display for the 3 5 Un...

Page 65: ...ple the boards are not properly connected only the bottom version button appears with a red button background C 3 4 3 5 Main Screen Figure C 18 3 5 Main Screen The main default screen Figure C 18 show...

Page 66: ...e C 19 Manual Override If the switch is in Manual or Off postion on PCB4 the touchscreen controls no longer control the compressor Moving the switch back to the Automatic position puts the unit under...

Page 67: ...d the connecting controller board Testing Allows for test mode of all shutdown events See Section C 5 for more information C 3 8 3 5 Alarms Screen Figure C 22 3 5 Alarms Screen The alarms screen Figur...

Page 68: ...prompted Maintenance Testing the System Alarms The Testing button allows the operator to create an Alarm or Shutdown condition to test the complete alarm network See section C 5 for additional informa...

Page 69: ...nance To view the service schedule press the Service icon on the 5 7 main screen Figure C 9 then select Maintenance from the list of headings When the Scroll icon located in the bottom left is blue th...

Page 70: ...nt from working properly C 7 1 Set Up Equipment Required PC with an Ethernet connection PC with a web browser such as Microsoft Internet Explorer Cat5 or better Ethernet cable C 7 2 Set Up Physical Co...

Page 71: ...server every 30 seconds When found the IP Address subnet mask and gateway are automatically obtained 2 IP Address using Static method Upon power up of the system the device will immediately begin usin...

Page 72: ...gure C 30 Login for Setup Pages 1 Once connected to the TotalAlert Embedded control system your browser will display the typical home page Figure C 29 2 Click Login on the menu bar in the left pane Th...

Page 73: ...Figure C 33 is used to con gure the facility network information and e mail server con guration NOTE Obtain the IP Address and DNS Name from the facility s Information Systems department Figure C 33 N...

Page 74: ...e 6 hours 24 hours 2 5 days and 10 days 1 Click System Trend Setup to access the System Trend Setup page 2 Select a time interval from the pull down list of options 3 Click the Submit button C 7 10 El...

Page 75: ...the Website The TotalAlert Embedded website allows the user to easily view the status of all activity pertaining to the medical air system By clicking the menu items to the left of the screen a user...

Page 76: ...escription of the service kit required to perform the maintenance function speci c to the medical air system installed Figure C 42 Maintenance Log Page Maintenance Log The Maintenance Log page Figure...

Page 77: ...d page Figure C 45 displays multiple items on the system measured at speci ed time intervals These items may include tank pressure dew point CO level and ambient temperature The time intervals may be...

Page 78: ...the pages to display the information available for download Maintenance Log System Trend or System Log 2 Click on the link to create a downloadable le located in the upper right above the displayed in...

Page 79: ...C 23 Oil Less Scroll Laboratory Air 4107 9006 25 11 Appendix C TotalAlert Embedded Control System Figure C 47 System Log Download Figure C 48 System Trend Download...

Page 80: ...alue is 10000 but the owner must set this to the Device Number they want for their BACnet Network Enter a name for the BACnet Device after assigning the ID see Figure C 49 C 8 3 BACnet Unlock After su...

Page 81: ...1059 Paragon Way Rock Hill SC 29730 888 4 MEDGAS 888 463 3427 Fax 803 817 5750 www beaconmedaes com...