FScurtis SEG-10, Operator'S Manual

Page 1: ...CAP881 OCTOBER 2012 REV A SEG Series OIL INJECTEDROTARY SCREW COMPRESSORS OPERATOR MANUAL SEG 5 SEG 10 SEG 7 5 SEG 15 ...

Page 2: ...tion System Flow Chart 23 Description 25 Protection Warning 27 Control Systems Electrical Circuit 27 Controller Operating Panel 29 5 0 Operation Inspection 30 Storage 31 6 0 Maintenance Maintenance Intervals 32 Air Filter Oil Filter 33 Air Oil Separator 34 Lubricant 35 Oil Analysis 35 Thermostatic Minimum Pressure Valves 36 Belts 36 Sheave 37 Fan Motor 38 Bearings 39 Air end Motor Removal 39 7 0 T...

Page 3: ...mprehended Alert signals Description of signals Danger Danger is used to indicate presence of a hazard that will cause severe personal injury death or substantial property damage Warning Warning is used to indicate the presence of a hazard which can cause severe personal injury or substantial property damage Caution Caution is used to indicate the presence of a hazard which can cause personal inju...

Page 4: ... CURTIS directly Explanations of safety symbols Operation manual Follow the instructions before using this compressor Confirm the direction of motor rotation before startup See Section 5 5 for instructions Caution before startup To restart compressor after a long period of being inactive rotate air end manually with the power off If it is difficult to rotate contact FS CURTIS directly ...

Page 5: ...CAP881 5 Danger Electric circuits Danger Rotating parts Danger Hot or noxious gas outlet Not Breathable Danger Heat Do not touch hot areas Rotation ...

Page 6: ... power supply before maintenance or service around electric equipment such as starter and motor Remove the 2 RED Shipping Brackets that secure the motor airend to the base frame before test run or startup Contact FSCURTIS or distributor for assistance if necessary ...

Page 7: ...connected before servicing or changing parts Lockout and tagout prior to maintenance 4 To ensure human safety and protect the facility from damage an electrical ground is necessary 5 Wear proper apparel during operation Protective clothing should be worn such as facemask or safety goggles and non slip footwear 6 Optional Dryer should be connected to separate 120V power source and follow Lockout Ta...

Page 8: ... Choose grounding cable according to the power range of the compressor Lockout and tagout power supply before working on control panel Lockout and tagout power supply before inspection and maintenance compressor is controlled by PID and may start automatically according to the setting Optional Dryer should be connected to separate 120V power source and follow Lockout Tagout procedures for inspecti...

Page 9: ...ressor 2 A clean low relative humidity and well ventilated area is best for safe operation The ambient temperature should be kept below 104 F 40 The air delivery of the compressor will decrease as the temperature gets higher 3 Reserve space for maintenance the distance between the compressor and the wall or other equipment must be greater than 28 inches 71 cm 4 There must be at least 3 feet of cle...

Page 10: ...ble of draining some of the condensate and cooling down the temperature of compressed air This will lead to more efficient dryer operation 8 If the air requirement is large in a short period of time install a higher volume air tank to reduce the frequency of full off load control 9 The ideal main piping is constructed around the factory as a loop which is better for delivering compressed air from ...

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Page 19: ... to help insure safety during maintenance of the compressor Per the National Electric Code the time delay fuses should be sized at 175 of the full load amperage FLA found on the motor nameplate Consult the Code if you want to use another style of branch circuit protection All internal wiring has been done at the factory Wiring of the power supply to the compressor should be done by a qualified ele...

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Page 21: ... the secondary rotor A As the rotors turn air is trapped in the cavity created by the mashing lobe and groove and reduced in volume or compressed It is then pushed through the successive cavities B until it reaches the discharge end of the compressor C and is sent to the oil separator During the compression cycle oil is injected into the compressor for the purpose of dissipating the heat of compre...

Page 22: ...SI in the oil separator to ensure a sufficient flow of oil to the compressor The compressed air is discharged to its point of use or enters the aftercooler on SEG 10 15 models where it is then cooled and discharged to its point of use A sufficient amount of oil is stored in the Oil Receiver Tank and is forced by the pressure of compression from the separator to the thermal by pass valve which regu...

Page 23: ...CAP881 23 4 0 System flow diagram and components function A System flow diagram and components function SEG 5 7 5 System Flow Diagram ...

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Page 25: ... is 212 F 100 Do not operate the unit over this temperature otherwise a trip will occur 4 Oil Receiver There is a sight glass on the bottom side of the receiver Maintain the oil level between H L On the bottom there is a drain valve remember to drain condensate water every time before startup In addition an oil fill hole for oil replacement is on the tank as well The larger cross section area desi...

Page 26: ...ns of radiator periodically with compressed air or with solvent B Oil Filter Oil filters help get rid of metallic particles and sludge from compressor oil in order to protect bearings and rotors After the first 500 hours of operation is reached follow the instructions for replacement Failure to do so may result in lack of oil which will lead to high discharge temperature and shorter bearing life C...

Page 27: ...e which makes it necessary to place the unit in a well ventilated area When the compressor is tripped due to a high discharge temperature the system is unable to restart unless the reset button is pressed after the system cools down F Control system and electric circuit 1 Control system 1 Start Overload Operation After motor start the solenoid valve is energized to keep the intake valve open and b...

Page 28: ...emand There is an AutoStop warning sign displayed on the controller The unit should not start more than 6 times per hour This is controlled by AutoStop time setting on AIMS controller Minimum is setting is 10 minutes default is 15 minutes 2 Electric Circuit The motor uses across the line start The compressor system is operated by an AIMS controller 3 Controller Refer to the AIMS Controller Manual ...

Page 29: ... of parameter UP UP key scrolls to the next display switches to the next menu or increases parameter value DOWN DOWN key scrolls to the previous display switches to the previous menu or decreases parameter value SHIFT ENTER The key is used as a shift key for the data being modified and an enter key for the menu being selected RETURN The key is used for returning to the upper menu LCD DISPLAY START...

Page 30: ...onds 9 Compressed air will be released immediately after pressing the OFF button B Inspection before start In order to protect the compressor and increase operation efficiency it is necessary to inspect the system prior to operation 1 Open both ball valves below the oil tank to drain any water Condensed water will cause bearing damage and reduce the lifespan of the lubricant 2 Check oil level Do n...

Page 31: ...placing the unit in operation When this is required do the following 1 Cover and seal all machine openings to prevent moisture and dirt from entering the unit 2 If the storage conditions are below freezing drain any condensate from the system and the after cooler on SEG 10 15 models Outdoor storage is not recommended ...

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Page 33: ...eset the filter service advisory in the controller and the machine will be ready for operation 6 3 Oil Filter The oil filter in the compressor system is a full flow replaceable canister type Initially the filter should be replaced after 500 hours of operation then every 2000 hours This element protects the compressor bearings from grit and dirt ingression throughout the system A dirty filter will ...

Page 34: ...essure from entire system 2 Using a strap wrench remove the old filter element 3 Clean the gasket mating surface with a clean rag 4 Apply a light film of oil to the new gasket on the filter element 5 Hand tighten the new filter element until the new gasket is seated against the mating surface 6 Continue tightening by hand an additional to turn 7 Reconnect power reset separator service advisory 8 R...

Page 35: ...ricants If other lubricants are used failures due to lubrication are not warrantable CAUTION Plugged filters coolers and orifices can result from mixing different lubricants and conditioners This will also void the warranty Be sure to always use CurtisLubePlus FSC 8000 in refilling your compressor Oil Analysis Oil analysis is an excellent tool to add to your compressor maintenance program At regul...

Page 36: ...Allow one minute after stopping the compressor for settling and the pressure to relieve 9 Remove the fill cap to see if more lubricant should be added and to insure that there are no leaks 6 7 Thermostatic Valve The thermostatic valve is a non adjustable temperature control valve On the compressor we use this valve to mix hot and cold oil It will begin to open at 150 155o F and be fully open at 17...

Page 37: ...lar should not exceed 1 16 Parallel misalignment occurs when the shafts are parallel but the face of the sheave is not in alignment Angular misalignment occurs when the shafts are not parallel An easy and effective method for checking the alignment in both directions is to use an accurate straight edge 1 Turn off the unit disconnect the power and lockout and tagout to prevent accidental restarting...

Page 38: ...ing grease will lose its lubricating ability over time not suddenly The type of grease used the temperature of operation and the speed of the motor effect the life of the bearing lubrication You should re grease the bearings every 2000 hrs or once a year Units in severe duty dusty locations or high ambient temperatures the time interval is 1000 hours A high quality ball or roller bearing grease wi...

Page 39: ...ng devices are necessary for the removal and installation of the air end motor A Turn off compressor B Turn off main power and lock out and tagout to avoid accidental start up C Remove all side access panels D Remove belt guard and belts from pulleys E Remove 3 hose fittings from the airend which are coming from the cooler F Remove 3 sensors 2 Pressure sensors 1 Temperature sensor G Unplug PD Posi...

Page 40: ... failure b High Air Temperature c Loose or missing electrical components d Pressure limit set too low e Motor overloads trip out f Low voltage Compressor does not build up to the desired pressure a Inlet valve partially closed b Belt slippage c Restricted inlet air cleaner d Excessive air demand e Defective pressure gauge f Pressure limit set too low g Excessive pressure drop across the separator ...

Page 41: ...d Compressor surges a Erratic air demand b Customer air system too small for supply c Minimum pressure valve d Pressure differential too low for the system conditions e Loose electrical connection between the controller and the solenoid valve f Faulty pressure transducer g Faulty solenoid valve h Faulty pressure relief valve Excessive Oil Consumption a Overfilled sump b Broken oil line c Plugged o...

Page 42: ...Exhaust air is restricted High power consumption a Plugged separator b Plugged aftercooler c Improper air pressure switch setting d Too low of a line voltage e Electrical phase imbalance f Imminent motor failure g Imminent air end failure h Belt slippage i Loose electrical connection Safety valve discharges a Over pressure not set correctly b Inlet valve not closing properly in relation to air dem...

Page 43: ... 0 Maintenance Log Model _____________________ Serial Number _____________________ Date Hourmeter Reading Changed Greased Motor Bearings Cleaned Cooler Checked Fitting Tightness Air Filter Oil Filter Oil Separator ...

Page 44: ...CAP881 44 NOTES ...