Scott Safety HUSH Operating Instructions Manual Download

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Stationary Air Compressor System Operating Instructions

Contents

Stationary Air Compressor Systems

Operating Instructions

SCOTT P/N 595134-01 REV C 1/12

IMPORTANT SAFETY INSTRUCTIONS

.................2

Safety Notations ..........................................3

Safety Labels ...............................................3

Limited Warranty

....................................................4

1 - Introduction .......................................................5

HUSH Air Compressor .................................7

Simple Air Compressor ................................7

2 - Features .............................................................7

General Description .....................................7

Routine Maintenance ...................................7

Simple Air System Components ..................8

HUSH Air System Components ...................9

Principle of Operation ................................10

Breathing Air Quality ..................................10

Simplified System Diagram

.......................11

3 - Starting and Operating the Stationary Air Com-

pressor System ..............................................15

Introduction

................................................15

Working with Compressed Air

...................15

Pre-Operation Checks ...............................16

Removing the Cabinet Enclosure .......16

Pre-Operation Check Procedures

.......20

Operation of the Compressor System .......20

Compressor Rotation .................................20

X4 Control Panel .......................................20

Operating the Compressor .......................22

Operating the Compressor ........................23

Operating the Compressor Continued...

....24

Compressor Stage Gauge Readings

.........24

Information Button .....................................25

Operating the Compressor ........................25

Service Notifications

..................................25

Operating the Compressor Continued...

....26

System Tolerances and Overrides

.............26

Use of the Purge ........................................26

Overrides

...................................................27

System Shutdown

......................................27

Charging the Storage System ...................28

Storage Cylinder Inspection

................28

Charging Storage Cylinders

................28

Cascade Volume Operation

................28

4 - Operator Maintenance Checks.......................29

Operator Maintenance Checks ..................29

Service Schedules

.....................................29

Condensate Container

...............................30

Electrical Fuses .........................................30

Simple Air Inlet Filter Cap ...................30

Inlet Filter ...................................................31

Purification System Moisture Indicator

......31

Compressor Drive Belt ..............................31

5 - Additional Features .........................................33

Auxiliary Air Outlets (Standard)

.................33

Regulated Pressure Outlet (Optional)

.......34

High Pressure Outlet and Gauge

........34

Low Pressure Outlet and Gauge

.........35

6 - System Administrator Responsibilities ........37

Modify System Settings

.............................37

Perform System Service ............................38

Calibrate the CO Monitor ...........................39

7 - Index .................................................................41
Maintenance Record ............................................43

Smart Fill are registered and/or unregistered marks of Scott Technologies, Inc. or its affiliates.

Summary of Contents for HUSH

Page 1: ...Stationary Air Compressor Systems Operating Instructions HUSH Air Compressor Simple Air Compressor ...

Page 2: ......

Page 3: ...ge Gauge Readings 24 Information Button 25 Operating the Compressor 25 Service Notifications 25 Operating the Compressor Continued 26 System Tolerances and Overrides 26 Use of the Purge 26 Overrides 27 System Shutdown 27 Charging the Storage System 28 Storage Cylinder Inspection 28 Charging Storage Cylinders 28 Cascade Volume Operation 28 4 Operator Maintenance Checks 29 Operator Maintenance Check...

Page 4: ...per use includes but is not limited to use without adequate training disregard of the warnings and instructions contained herein use of the equipment for purposes not included in these instructions and failure to inspect and maintain the equipment 5 All electrical connections shall be installed by a qualified electrician in accordance with applicable electrical codes and shall include proper groun...

Page 5: ...at is important but not hazard related Danger is used to indicate the presence of a hazard that will cause severe personal injury death or substantial equipment damage if the warning is ignored Warning is used to indicate the presence of a hazard which may cause severe personal injury or substantial component damage if the warning is ignored Caution is used to indicate the presence of a hazard whi...

Page 6: ... or damage caused by repairs of or alterations to SCOTT STATIONARY BREATHING AIR COMPRESSOR PRODUCTS including HUSH AIR COMPRESSOR PRODUCTS made by owner or any third party unless expressly permitted by SCOTT product manuals or by written authorization from SCOTT To obtain performance under this warranty and as a condition precedent to any duty of SCOTT the purchaser must present such products to ...

Page 7: ...harging breathing air cylinders for use in respirators or self contained breathing apparatus SCBA The com pressor and purification system are designed to purify air to meet or exceed recognized air standards as specified by the Compressed Gas Association CGA G 7 1 and National Fire Protection Association NFPA 1989 Before use this equipment must be properly installed and inspected by a SCOTT Safety...

Page 8: ...Stationary Air Compressor System Operating Instructions 1 Introduction 6 HUSH Air Compressor Simple Air Compressor ...

Page 9: ...low on the next pages Routine Maintenance The reliable operation of this equipment depends on proper care and routine maintenance The operator must be trained by an authorized SCOTT Safety technician in the proper operation of the stationary breathing air system The operator must read understand and adhere to all safety precautions and pre operation tasks as described in this manual All scheduled ...

Page 10: ...ges Four Stage Compressor shown 2 Purification Filters 3 Electric Box Fuse Location 4 Fuses 2 5 Condensate Container 1 Inlet Filter 2 Oil Fill Cap 3 Interstage Relief Valve 1 2 3 Model Number Open Units NOTE The actual appearance of the equipment may vary depending on the model and options installed 2 5 3 4 1 ...

Page 11: ...ons 9 HUSH Air Compressor System Components 1 Inlet Filter 2 Stage Gauge Panel 3 Oil Fill Cap 1 Purification Filters 2 Condensate Container 3 Pressure Relief Valve 4 Electrical Box Fuse Location 3 1 2 4 3 1 2 Compressor Serial Number HUSH Air Pressure Relief Valves ...

Page 12: ...s on the horse power and therefore the air output capacity of the compressor The higher the air output the more purification elements are needed The purification system further dries the air and removes other impurities From the purification system the air can go directly to charging breathing air cylinders or can be sent to high pressure storage cylinders and maintain the pressure in the storage ...

Page 13: ...ir Compressor System Operating Instructions 11 Simplified System Diagram NOTE The illustration represents a simplified diagram for the purposes of basic operation Outlets connection points and optional equipment are not shown ...

Page 14: ...run in either AUTO or MANUAL mode In AUTO mode the compressor will automatically restart when storage pressure drops approximately 500 psi below the maximum system pressure When in MANUALmode the compressor stops after purging and must be restarted manually NOTE If the CO or Dew Point monitor is not installed on your system the X4 Controller will display N A after the parameter on the LCD screen T...

Page 15: ...in weight approximately 200 lbs each and are always installed vertically Each DOT cylinder stores 509 standard cubic feet at 6000 psi Each ASME cylinder has the capacity to store 454 standard cubic feet SCF at 5000 psi or 525 SCF at 6000 psi DOT cylinders must be visually inspected and hydrostatically tested by a licensed cylinder re tester in accordance with the appropriate US Department of Trans...

Page 16: ...re settings for breathing air cylinders such as 2216 psi and 4500 psi The two pressure settings are factory set and can be adjusted only by a SCOTT trained and certified service technician See the procedure on filling breathing air cylinders for instructions on operating the dual pressure regulator Handling and Charging Compressed air may be directed to a charging station for charging breathing ai...

Page 17: ...R charge a breathing apparatus or ASME storage cylinder beyond the rated working pressure NEVER fill a breathing air cylinder that has not been inspected according to this instruction and verified to be acceptable for filling REMEMBER Compressed air can kill Treat it with respect Training is required before use of this equipment Improper use of this equipment may result in serious injury or death ...

Page 18: ...dge from the protruding pins Be careful not to bend the enclosure pins Place the access panel in a safe place while performing the pre operation checks ALWAYS replace the panel prior to starting the compressor To replace the enclosure panel 1 Tilting the panel at an angle place the bottom edge of the panel onto the pins Do not replace the panel without first setting the bottom pins correctly 2 Pos...

Page 19: ...ver to loosen the eleven 11 finger screws on the access panel 2 Tilt the bottom of the panel out slightly away from the enclosure 3 Pull the panel straight out to remove Place the access panel in a safe place while performing the pre operation checks ALWAYS replace the panel prior to starting the compressor To replace the enclosure panel 1 Tilting the panel at an angle position the internal locato...

Page 20: ...If any connection is loose or damaged DO NOT start the compressor until all connections have been properly repaired and thoroughly inspected 6 C h e c k t h e c o m p r e s s o r o i l l e v e l Check the compressor oil level prior to each use To check the oil remove the oil fill cap and check the oil level reading Replenish as necessary using only Anderol 500 oil or XL 700 oil available from your...

Page 21: ...3 Starting and Operating Stationary Air Compressor System Operating Instructions 19 NOTES ...

Page 22: ... Com pressor Breathing Air System unattended while the compressor system is operating or in use Hearing protection may be required when using the Sta tionary Air Compressor system for extended periods of time Refer to the personal safety guidelines or require ments of your organization Hearing protection may be required when using the Stationary Air Compressor system for extended periods of time R...

Page 23: ...ntroller will display N A after the parameter on the LCD screen If monitored conditions are out of tolerance the controller emits a visual and audible alarm and will subsequently shut down the compressor The controller allows the system to run in either AUTO or MANUAL mode In AUTO mode the compressor will automatically restart when storage pressure drops approximately 500 psi below the maximum sys...

Page 24: ...tly below the X4 Controller digital display 3 The display will show the current Service Due dates and say Push Operate Info or Service Press OPERATE on the keypad Remember you can press BACK at any time to return to the previous display 4 The display will read AUTO or MANUAL Select by pressing the key below the desired mode AUTO F1 Key recommended for on site operation when a constant supply of co...

Page 25: ...ssor Pressure and Storage Pressure gauge readings Also monitor the Compressor Stage Gauge Readings as instructed on Page 26 of this instruction 7 When the system pressure reaches approximately 2500 psi adjust the Flow Control to obtain a 50 50 red green reading in the Flow Meter only on units with either the SCOTT CO or DP monitors This provides the correct sample flow rate to the carbon monoxide ...

Page 26: ...ontroller is inAUTO mode the compressor will restart when pressure drops approximately 500 psi below maximum system pressure If the storage pressure was already FULL when the system was started the display will say Storage Full and the compressor will still restart automatically when the pressure drops If all Compressor Operating Parameters are in tolerance the system is ready to fill breathing ai...

Page 27: ...the Compressor continued on the next page After initial system boot the operator may press the INFO button on the X4 Controller to access current Run Time and Schedule information for the compressor system Information Button 4 Press the F1 button under NEXT to see the available screens The sequence of displays is as follows Total Hours of Compressor Run Time HRS MIN Output Air Temp CO Level Dew Po...

Page 28: ... may be programmed by the System Administrator Operating the Compressor Continued Press the Purge Button to begin the Purifier Purge Cycle When the readings reach ALARM levels the operator has the option to Purge the suspect air which may cor rect the problem or to keep operating the compressor When the readings reach the SHUTDOWN levels the operator must select OVERRIDE to continue producing air ...

Page 29: ...mpressor will stop Always allow the compressor to fully charge the storage system unload and go through a cool down cycle before final shutdown Failure to do so can lead to premature wear and or damage to the compressor and its components System Shutdown 2 Turn OFF the external power source wall mounted switch On compressor systems where the CO or Dew Point monitors are not installed it is also th...

Page 30: ...quirements DOT cylinders must be visually inspected and hydrostatically tested by a licensed cylinder re tester in accordance with the appropriate US Department of Transportation DOT specification or applicable DOT exemption or in accordance with the appropriate Transport Canada TC Permit of Equivalent Level of Safety Depending on when the DOT storage cylinders were purchased this may be five 5 or...

Page 31: ... hundred 100 hours of compressor running time the following maintenance should be performed by a trained technician Replace the air intake filter element Change the compressor oil Check the Auto Drain system Check all other auxiliary systems The air quality produced by the LIBERTY System should be checked regularly at the following intervals Every thirty 30 days If installed calibrate the Carbon M...

Page 32: ...thorough system check before using the system again Condensate Container If operating the compressor for an extended period of time be aware of the level of condensate in the condensate container The container should be drained when it is approximately three quarters 3 4 full Compressor condensate contains lubricating oil and or substances which must be disposed of in accordance with local State a...

Page 33: ...ntenance procedures If the indicator is blue all cartridges are in good operating condition However the purification filters should be changed every 50 hours of operation even if the indicator is still blue Optional Purification Moisture Indicator Indicator may be located at the output end of the hose Inlet Filter The operator should check the inlet filter located on top of the compressor after pr...

Page 34: ...Stationary Air Compressor System Operating Instructions 4 Operator Maintenance 32 NOTES ...

Page 35: ...auxiliary air outlet to charge a self contained breathing air SCBA cylinder while the SCBA is being worn unless during an extreme emergency situation Persons operating the air supply and wearing the respirator will be in close proximity to the cylinder and valve assemblies If any of these components fails there is an increased risk of serious personal injury or death ALWAYS make sure that the auxi...

Page 36: ...let according to the manufacturer s user instructions for the air receiver Use the High Pressure Gauge to determine existing pressure in the receiver 3 To access high pressure air SLOWLY turn the Variable Pressure Regulator valve 4 When finished hand tighten any bleed valves and carefully remove the selected air source from the high pressure outlet NEVER use any auxiliary air outlet to charge a se...

Page 37: ...es and carefully remove the selected air source from the low pressure outlet If the low pressure air supply outlets are used for pneumatic tools DO NOT use the outlets to supply respirators unless the outlets are cleaned and the air quality from the outlets is verified as acceptable according to ANSI CGA specification G 7 1 Grade D or better Lubricants from the pneumatic tools or tool air lines ma...

Page 38: ...Stationary Air Compressor System Operating Instructions 5 Additional Features 36 NOTES ...

Page 39: ...and operating the BreathingAir Compressor system according to the Operator s Instructions provided with the system These tasks can only be accessed when the compressor system is powered up but the compressor itself is not running Follow the prompts on the display screen for each operation Remember you can press BACK at any time to return to the previous display Modify System Settings Perform Syste...

Page 40: ...inistrator that the breathing air produced by the system will always fall within the established limits Enabling the Override function permits the Operator to continue producing breathing air in the event of a life threatening emergency where breathing air is required and it is determined to accept the associated risks To Enable Disable the OVERRIDE Feature 1 After Password section the display wil...

Page 41: ...Compressor Operation Select YES F1 button if an air sample has been taken and certified to meet the breathing air requirements for your respiratory protection program This will automatically set the current date as the air sample service date 7 If the CO Sensor is installed and you select NO F3 button you will proceed to the CO Calibration procedure below b Adjust the Flow Meter to 50 50 with the ...

Page 42: ...ation Port Connect 20 PPM CO Adjust Flow to 50 50 Level on Indicator Next 2 3 1 Calibration Port 2 Flow Control Dial 3 Air Flow Adjustment Eye 1 Calibrating the CO Monitor Continued j Select DONE F2 button The X4 Controller will exit the Perform System Service and return the display to the start up screen that says SCOTT Safety 800 247 7257 PRESS F2 BUTTON BELOW TO BEGIN as when first starting the...

Page 43: ...electrical box location 8 inlet filter checking 29 location 8 model number 7 oil fill cap location 8 operation AUTO or MANUAL mode 20 pressure relief valves location 8 principle of operation 10 purification system checking 29 location 8 shutdown 27 stage gauge panel location 8 system diagram 10 Condensate container draining 28 location 8 Control panel description 12 Controller X4 location 18 maint...

Page 44: ...ir 15 Purification system moisture indicator checking 29 description 12 R Routine maintenance general 7 S Safety working with compressed air 15 Safety labels 3 Safety notations 2 Scott Safety contact information 5 Storage cylinders description 13 System tolerances and overrides 24 System Administrator Responsibilities 37 Modify System Settings 37 Perform System Service 38 Calibrate the CO Monitor ...

Page 45: ...43 Maintenance Record ...

Page 46: ...44 NOTES ...

Page 47: ......

Page 48: ...EV C 1 12 SCOTT Safety Monroe Corporate Center PO Box 569 Monroe NC 28111 Telephone 1 800 247 7257 FAX 704 291 8330 www scottsafety com Printed in USA Manual Price 25 00 Copyright 2012 Scott Safety All Rights Reserved ...

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