Alemite Carbon Shield Installation, Operation And Maintenance Manual Download Page 1

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INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

Summary of Contents for Carbon Shield

Page 1: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL ...

Page 2: ......

Page 3: ...itors every component and reports warnings to maintenance personnel The system has an adaptive control mode that learns the operating parameters and warns against anomalies Refer to this comprehensive manual to guide the installation operation commissioning and maintenance of your Carbon Shield system Sections are devoted to technical specifications component listings available accessories and tro...

Page 4: ...2 www alemitecarbonshield com Fig 01 ...

Page 5: ...Alemite Carbon Shield Service Guide 3 www alemitecarbonshield com Fig 02 ...

Page 6: ...an optional air heater Heated air can help maintain the correct oil air ratio in cold climates The PLC controls air temperature by cycling the air heater on and off according to signals received from the air temperature thermocouple Mist Pressure Air is routed to a venturi in the mist head which lowers the static pressure and lifts oil from the oil reservoir The venturi effect cools the oil partic...

Page 7: ...ontents 4 8 Guide To Illustrations 8 9 System Components and Features 9 9 Electrical System 9 Input Power 9 Cabinet 9 9 Programmable Logic Controller PLC 9 Human Machine Interface 10 PLC Password 10 PLC Inputs Outputs 10 11 Mist Head Assembly 11 Oil Mist Outlet 11 Mist Pressure 11 Relief Valve 11 12 Tank Assembly 12 Loader Fitting 12 Oil Heater 12 Capacitive Level Sensor 12 table of contents ...

Page 8: ... Oil Storage System 14 Oil Temperature 14 14 Backup Generator 14 15 Cabinet Cooler Optional 15 15 Cabinet Purge Optional 15 15 Status Lights 15 15 Solenoid Valves 15 16 Installation 16 16 Site Preparation 16 17 Systems Connections 17 Air System Connections 17 Inlet Air 17 Oil Inlet 17 Mist Oulet 18 Without Backup 18 With Backup 18 18 Electrical System 18 Power 18 table of contents ...

Page 9: ...27 Using Change Parameters Feature 27 28 Using Adaptive Mode Feature 28 29 Monitoring Function 29 30 Local Alarm 30 31 Remote Communication and Alarm 31 Hard Wired Relay General Alarm Signal 31 Internet Based Communicaton 31 33 Interface to Native DCS Networks 33 33 PLC Program Loading 33 34 Switching from Main to Backup Generator 34 35 Maintenance Checklist 35 36 Filter Elements 36 Oil Inlet 36 A...

Page 10: ...lectrical Systems 46 47 Parts List 47 52 Wiring Diagrams 49 Fig 90 PLC Analog Input Output module wiring 49 Fig 91 Thermocouple Module Wiring 50 Fig 92 Relay Wiring 51 Fig 93 Schematic Diagram 52 54 References 53 Carbon Shield Nomenclature 53 Fig 94 General Arrangement Drawing 54 Fig 95 Installed Arrangement Drawing 55 table of contents ...

Page 11: ...ite s Carbon Shield TM consoles operate on 120 240 VAC 50 60 Hz single phase supply The internal jumper selectable power supply transforms incoming voltage into 24 VDC for the PLC HMI and various sensors and control devices Cabinet The NEMA 4X stainless steel cabinet has center locking weather sealed doors with a three point locking system The door is sealed with foam in place gasket and all penet...

Page 12: ...sor password access is limited to the Change Parameters screen only All other screens in the HMI are for viewing information and do not require password The PLC receives 4 20 mA signals from the pressure vacuum sensors that indicate mist head and mist outlet pressure Air and oil temperature signals from thermocouples installed in the air and oil streams 4 20 mA signals from the oil level sensor Th...

Page 13: ...the mist head and tank through the outlet piping Fig 06 At the mist outlet the customer connects a 2 inch distribution line to the 150 pound stainless steel screw flange provided on the outside of the control cabinet Mist Pressure The mist pressure sensor mounts on the PLC box and connects to the top of the reservoir by rigid tubing Fig 07 It sends a signal to the PLC to monitor and control mist p...

Page 14: ...actory The level sensor is UL CSA certified for service in Class I Division 2 environments and measurestheoillevelinthereservoirwithaccuracy It is calibrated to work with oil only Fig 12 Oil Heater The oil heater is an immersion type rated at 500 watts The oil heater is rated for 120 VAC or 240 VAC depending on the application and the housing meets NEMA 4 7 specifications Fig 13 Air Pressure Contr...

Page 15: ...ssure transducer and pneumatic booster Fig 14 to sense and adjust mist pressure No incoming air regulator adjustments are necessary after the initial manual setting of 70 95 psi 4 92 6 68 kg cm2 The transducer booster unit maintains optimum mist pressure nominally 20 inches of water column by regulating air pressure at the mist head inlet based on signals it receives from the PLC The HMI provides ...

Page 16: ...ture by cycling the oil heater on and off The oil temperature is displayed in the HMI The analog thermometer also provides the operator a readout of the oil temperature Fig 18 Backup Generator The backup generator is used when maintenance or repairs are being done on the main unit The backup generator is mounted inside a NEMA 4X enclosure of the same material as the enclosure of the main generator...

Page 17: ... areas The system works by supplying compressed air at proper flow and pressure to eliminate or reduce entry of contaminants to the enclosure Status Lights Red and green status LED indication lights are mounted on the top of each Carbon Shield cabinet Fig 21 The status lights are controlled by the PLC The green lamp is illuminated whenever the Carbon Shield system is operating normally and all ope...

Page 18: ... 4m x 3 0m for console and backup unit 8 feet x 5 feet 2 4m x 1 5m for console unit alone Once the site is established secure the console to a level concrete surface Use of a 4 to 6 inch 10cm to 15cm concrete riser pad between the floor and the oil mist console is a common practice 1 Prepare the surface with four anchor bolts 3 8 or 10mm at the required locations eight bolts if a backup unit is in...

Page 19: ...nch ball valve in the oil line inside the oil mist cabinet Should the system require maintenance this manual shut off valve permits isolation from the refill pump separate from the oil mist system without locating and turning off the pump Oil pressure delivered to the inlet connection must not exceed 100 psi 7 03 kg cm2 To prevent contamination or clogging of the piping fittings or both Seal all a...

Page 20: ...s incoming 120 240 VAC 20 10 amp line power to the Carbon Shield console The power connection is made at the disconnect switch in the lower left hand corner inside the cabinet Wiring must be done in accordance with hazardous location requirements by qualified personnel Fig 29 Potentially hazardous conditions May result in death severe injury or equipment damage All wiring must be done in accordanc...

Page 21: ...tomer The Ethernet module requires 2 x 8 pin RJ 45 jacks The jack is located beneath the front panel of the module Fig 31 DP 9 female connector and terminals for power supply and functional ground are located beneath the front cover of the PROFIBUS module fig 32 The Modbus module is supplied with an integrated RS 422 485 serial interface 15 pin connector located under the front cover of the Module...

Page 22: ... must be provided at the bottom of the cabinet to maintain cabinet sealing when the drain is not in use Before Start Up Inspect your Carbon Shield console Make sure components electrical and mechanical are securely connected Check wiring ensure terminal screws are secure The tank drain ball valve must be CLOSED before oil is loaded into the tank Fig 35 Ensure that the unit is properly grounded thr...

Page 23: ...il tank Start Up Sequence 1 Adjust internal pressure regulator inside cabinet to 80 psi 5 63 kg cm2 Fig 37 2 Turn on power to the oil mist unit with the main power switch at the lower left side inside the cabinet Fig 39 This energizes the PLC and HMI 3 As unit is starting up observe HMI display Four choices are displayed on the HMI Transfer Start Control Panel and Task Bar Fig 41 3a Choose Start o...

Page 24: ...upper left corner Fig 47 9 Touch the User Name window Fig 48 Important Note User name and password are factory set and supplied at the time of system delivery 4 The 4 choices are displayed again choose Start Fig 44 5 The home page of the Alemite Carbon Shield unit is displayed Fig 45 6 Note SETUP flashing in upper right corner Fig 42 Fig 46 Fig 47 Fig 48 ...

Page 25: ...the password on the pop up keypad on the screen and then press the Enter key the backward facing arrow on the keypad s lower right corner Display returns to the Main Menu screen when user name and password are successfully entered Fig 51 Important Note Both the username and password functions are timed and will revert to the set up screen if no entries are made after a short period of time Fig 49 ...

Page 26: ...f the oil level is not within 5 of the indicated level your level sensor needs to be calibrated 13 Drain the tank below the zero mark on the level gauge 14 Note Due to the size of the orifice in the sight glass and depending on the oil viscosity and temperature the oil level in the sight glass will take longer than the actual oil level inside the tank to change During the following procedure alway...

Page 27: ...he top of the mist head Important Note The nozzle capacity selection instructs the PLC to load default parameter values at 20 in H2O which is the Alemite system s Design Manifold Pressure 18b A small green indicator will appear in the upper right corner of the button when a selection is made Fig 58 18c If an incorrect nozzle size is selected simply select the proper nozzle size the green indicator...

Page 28: ...I displays a green dot on the corner of the respective button when an option has been activated Important The bulk option should only be selected if the unit is equipped with an Alemite bulk oil tank system with a level switch Enabling this option when the Alemite bulk oil system with level switch is not present will cause the system to issue false alarms 23 The green status light on top of the un...

Page 29: ...nds etc By selecting the Change Parameters button the user can access the screen below Fig 69 3 By selecting the Air Flow button the user can access the Flow Parameters screen The user can either adjust the mist pressure value so that the air flow reading matches the sum of the CFM of the fittings used in the installation at 20 inches of water column or adjust the mist pressure to produce the mist...

Page 30: ...tive Mode is a password protected feature that can be accessed at any time through the Set Up or the Change Parameter screen following the steps below 1 Make sure the system is running as desired without leaks or blockages 2 Go to the Main Menu screen Select the Set Up button Fig 72 3 Enter the user name and password Fig 73 4 Select the Set Up button again Fig 72 5 Select the Adaptive Mode button ...

Page 31: ... the Main Menu screen of the HMI Fig 77 Local Alarms The PLC performs an ordered series of control set point checks for the maximum and minimum values of each function The controller identifies captures and time stamps the fault if the current value exceeds the maximum setting high alarm or is less than the minimum setting low alarm To access press the Alarms button on the Main Menu screen of the ...

Page 32: ...C detects the air thermocouple input to be out of range There is no time delay 10 Wrong CFM Hi Issued when the mist pressure is at 20 H2O or other chosen set point but the mist flow is greater than the default value by 30 This may be an indication of having selected a nozzle size in the HMI Set Up screen that is smaller than the one actually installed Another possible cause is a large leakage in t...

Page 33: ...o time delay 3 Oil Temp Alarm Lo Issued when the oil thermocouple detects an oil temperature below 85 F 29 4 degrees C There is no time delay 4 Oil Temp Sensor Fault Issued when the oil thermocouple input to the PLC indicates out of the 4 20mA range There is no time delay 5 Oil Sensor Fault Level sensor input to the PLC indicates to be out of the 4 20mA range There is no time delay 6 Oil LVL Alarm...

Page 34: ...equest Alemite supplies a memory map of operating variables and alarms including the type location and size As an option Carbon Shield units can be factory configured for interface communication with native DCS networks Modbus RS 422 485 RTU in slave mode is the preferred method Modbus over Ethernet can also be offered per customer request For general information about Modbus please refer to http ...

Page 35: ...he PLC Important Note Power to the Carbon Shield Unit must be turned off before continuing Failure to turn off the power before remove the PLC will erase the PLC memory and render the PLC inoperable 2 Remove the original and insert new MEMORY CARD 3 Apply power to the PLC the program on the Memory Card automatically loads to the PLC memory 4 You should notice the RED ALARM light at this time 5 Fol...

Page 36: ... and backup generator starts Fig 87 1 Open the mist outlet valve of the backup unit 2 Switch the 3 way air inlet valve to supply air to the backup generator 3 Close the main unit mist outlet valve To switch back to the main generator the process is reversed 1 Open the mist outlet valve of the main unit 2 Switch the 3 way air inlet valve to supply air to the main generator 3 Close the backup unit m...

Page 37: ...Inspect all gasket connections o Drain and clean oil tank oil pick up screen Filter Elements Oil Inlet The oil filter element can be changed while the console is operating Important Note Always close the ball valve in the Carbon Shield cabinet and the air supply valve to the refill pump before changing the filter element Follow the proper lockout tagout procedures Air Filter Regulator The filter r...

Page 38: ...roblem To display alarm messages press the Alarm Screen button on the main menu screen of the HMI Fault types values and the time they occurred are logged in memory and can be retrieved either locally or from a remote location as described in this manual If the first solution doesn t clear the alarm then proceed to the next possible solution If the alarm still exists the severity of the problem ma...

Page 39: ...Alemite Carbon Shield Service Guide 37 www alemitecarbonshield com ...

Page 40: ...voir verify oil level is in the operating range Verify oil consumption rate from the HMI 1 3 Confirm oil adjustment screw has not been changed from factory setting Adjust if needed If change occurred in this setting it will be time stamped in the alarm log 1 4 Check oil suction screen for obstruction 2 Oil or Air Heater Malfunction 2 1 Confirm oil and air temperature Factory default is 100 F 37 8 ...

Page 41: ... 68 kg cm2 for 13 CFM 21 CFM units 3 Mist pressure set point set too low 3 1 Press the Parameter Values button on the main menu screen to display the mist pressure value Factory default is 20 inches H2O column or 50 mBar 3 2 Adjust mist pressure by pressing the Change Parameter button on the main menu then the Air Flow Parameters then the or buttons on the Flow Parameters screen to the desired mis...

Page 42: ...ure may be the result of blockage in mist fittings due to accumulation of wax in the mist fittings from paraffin based oils Check the alarm log for blockage alarm and time repair or replace fittings as needed 2 2 Check for kinks in mist supply lines repair as needed Blockage alarm will be logged and time stamped in alarm log 2 3 Vent lines plugged or kinked the CS may indicate blockage alarm Trans...

Page 43: ...nsure that the mist pressure is above 10 in H2O If this is the case please see Low Mist Pressure to continue the troubleshooting 1 4 Check the operation of control relay R0 and fuses F1 F9 Replace as needed Refer to Wiring Diagram 1 5 If there is a 24 Vdc signal from the PLC to the coil of relay R0 and the relay is not operating fuse F1 may be open If there is no 24Vdc to coil fuse F9 may be open ...

Page 44: ... takes more than one hour 1 Automatic Refill Valve inside the cabinet may be half open 1 1 Ensure that the oil supply valve to the reservoir is fully open 2 Oil Refill Solenoid malfunction 2 1 Check the oil level in the bulk oil tank to ensure oil was not depleted Refill as needed 2 2 Check air pressure to supply pump on the bulk oil tank which should be between 60 80 psi 4 22 5 63 kg cm2 2 3 Chec...

Page 45: ... Please change over from the main unit to the backup unit Turn off the power to the main unit and contact Customer Service at 1 800 822 4579 Insufficient amount of oil mist or no mist produced Potential problem may be unrelated to the Carbon Shield Unit internal workings 1 Distribution line obstruction 2 Console Reservoir overfilled 3 Foreign material in application fitting s 4 Improper oil or inc...

Page 46: ...r and 5 gallon or 18 9 L reservoir Air heater Power 500 or 1000 Watt Nominal Temp 100 F 37 8 C Temp Range 0 180 F 17 8 to 82 2 C Air Supply Pressure Range 70 150 psi 4 92 10 55 kg cm2 Quality Instrument air Dry Regulated air pressure to generator Nominal 80 psi 5 63 kg cm2 Min Max 65 95 psi 4 57 6 68 kg cm2 Mist Pressure Head Nominal 20 Inches H2O Range 10 40 Inches H2O depending on the nozzle siz...

Page 47: ...de Analog Inputs 3 4 20 mA Digital Outputs 7 Analog Outputs 1 Digital Inputs 1 Thermocouple 2 inputs max Alarms High low ranges for oil air temperature mist pressure and oil level Leakage blockage change in oil adjustment screw setting and abnormality of any transducer operation Graphic Display Temperature pressure and mist density trending Security Two level password access Mist Density Quantifia...

Page 48: ...0 H2O 1 4 Tube 387603 2 Job specific SST Mist Fitting 0 16 SCFM 20 H2O 1 4 Tube 387603 4 Job specific SST Mist Fitting 0 24 SCFM 20 H2O 1 4 Tube 387603 6 Job specific SST Mist Fitting 0 39 SCFM 20 H2O 1 4 Tube 387603 8 SST Mist Fitting 049 SCFM 20 H2O 1 4 Tube 387603 10 Job specific SST Mist Fitting 0 68 SCFM 20 H2O 1 4 Tube 387603 16 Job specific O Ring Mist Head 171018 44 Y Y 4 parts in package ...

Page 49: ...heater 120 VAC and 500W 387849 15 Y Job specific Air heater 240 VAC and 1000 W 387849 2 Y Job specific Air heater 240 VAC and 500 W 387849 25 Y Job specific Oil heater 120 VAC and 500 W 387830 1 Y Job specific Oil heater 240 VAC and 500 W 387830 2 Y Job specific PLC memory cartridge w SW 388173 Y POWER SUPPLY PLC 388097 Y THERMOCOUPLE MODULE 388100 Y THERMOCOUPLE 387831 Y PLC 388096 Y HMI 387878 Y...

Page 50: ...s ACCESSORIES Manual Refill Pump 388034 Y Job specific Mist Collector Container 388235 Y Job specific Bulk Oil Storage Tank 388220 Job specific Manifold Assy Mist 388236 Y Y Sightglass Vent 388241 Y Y Sun Screen 388234 Prue Mist Kit 388251 Purge Mist Kit 388252 Drain Leg Kit 388253 Tube 3 8 OD 10 ft 387990 Tube 1 4 OD 10 ft 387989 BULK OIL TANK PARTS Job specific Y Y Y ...

Page 51: ...Alemite Carbon Shield Service Guide 49 www alemitecarbonshield com Wiring Diagrams PLC Analog Input Output module wiring Fig 90 Fig 90 ...

Page 52: ...50 Alemite Carbon Shield Service Guide www alemitecarbonshield com Wiring Diagrams Thermocouple Module Wiring Fig 91 Fig 91 ...

Page 53: ...Alemite Carbon Shield Service Guide 51 www alemitecarbonshield com Wiring Diagrams Relay Wiring Fig 92 Fig 92 ...

Page 54: ...52 Alemite Carbon Shield Service Guide www alemitecarbonshield com Wiring Diagrams Schematic diagram Fig 93 Fig 93 ...

Page 55: ...e Air Heaters Control Communication Module A 120 VAC A 500 W A Local PLC HMI 4 None B 230 VAC B 1000W C Other 5 Modbus C NONE 5 7 4 4 General Configuration Area Reservoir Capacity Nozzle CFM 5 7 Hazardous 2 3 Gallon Stainless Steel 1 1 CFM 4 5 Gallon Stainless Steel 2 2 3 CFM 3 4 3 CFM 4 9 7 CFM 5 13 CFM 6 21 CFM Accessories Certification Refill Option Others U UL A Manual 1 None B Auto 2 HMIProte...

Page 56: ...54 Alemite Carbon Shield Service Guide www alemitecarbonshield com References General Arrangement Drawing Fig 94 Fig 94 ...

Page 57: ...References Installed Arrangement Fig 95 Fig 95 www alemitecarbonshield com ...

Page 58: ... 1057 521 Corporate Center Dr Suite 100 Fort Mill SC 29707 Toll Free U S 866 4 Alemite Toll Free Canada 800 267 8022 International 803 802 0001 Fax U S 800 648 3917 Fax Canada 800 267 2880 Fax International 803 802 0192 www alemite com LITXXX 03 12 ...

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