Nuvair MCH36 Silent Touch Operation Manual Download Page 21

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MCH36 Silent Touch

Nuvair

Page 21

www.Nuvair.com

PHASE FAIL ALM

The compressor rotation is incorrect. The system shuts down immediately and sounds an alarm.

REPLACE 123 PISTON RINGS

First, second, and third stage piston ring replacement required. Alarm sounds.

REPLACE 123 RINGS RESET

First, second and third stage piston ring replacement alarm has been reset.

REPLACE 4 COMPLETE

Fourth stage piston and cylinder replacement required. Alarm sounds.

REPLACE 4TH STAGE RS

Replace fourth stage piston and cylinder alarm has been reset.

REPLACE COND SEPARATOR

Condensate separator replacement required. Alarm sounds.

REPLACE COND SEPERATOR R

Condensate separator replacement required alarm has been reset.

REPLACE DRIVE BELT

Drive belt replacement required. Alarm sounds.

REPLACE HI PSI CAN RS

High-pressure filter canister replacement alarm has been reset.

REPLACE HP FILTER CAN

Replacement of high-pressure filter canister required. Alarm sounds.

REPLACE HP FLEX HOSE RS

High-pressure flex hose replacement alarm has been reset.

REPLACE HP FLEX HOSES

Replacement of high-pressure flex hoses required. Alarm sounds.

REPLACE INTERSTAGE TUBE R

Replacement of interstage cooler tubes alarm has been reset.

REPLACE INTERSTAGE TUBES

Replacement of interstage cooler tubes is required. Alarm sounds.

VALVE SERVICE 123 INSP

Inspection and replacement as necessary of first, second, and third stage valves required. Alarm sounds.

VALVE SERVICE 1234 REPLC

Replacement of first, second, third, and fourth stage valves required. Alarm sounds.

4.8

Nuvair Page

This page is locked and only for qualified technical support to enable and disable alarms.

5.0

General Safety Rules

The compressor must only be used by qualified personnel. They must fully understand the arrangement and
function of all the controls, instruments, indicators, warning lights and the various information labels.

Summary of Contents for MCH36 Silent Touch

Page 1: ...Operation Manual MCH36 Silent Touch ...

Page 2: ...MCH36 Silent Touch Nuvair Page 2 www Nuvair com Notes ...

Page 3: ...n contained within Nuvair however retains the right to modify its contents without notice Under Nuvair s system of continuous improvement certain components may be updated or changed as higher quality or more efficient parts and assemblies become available Nuvair will make every effort to update manuals as parts and functional aspects change However the look or location of components on your produ...

Page 4: ...ide 16 4 2 Overview Screen 16 4 3 Alarm History Screen 17 4 4 Service Hours Screen 17 4 5 Gauges Screen 18 4 6 Alarm Configuration Screen 18 4 7 Alarm Events and Descriptions 18 4 8 Nuvair Page 21 5 0 General Safety Rules 21 5 1 Protective Clothing 22 5 2 Emergency Equipment 22 5 3 Checks and Maintenance 22 6 0 Safety Information Labels Location Description 22 7 0 System Components 23 8 0 Compress...

Page 5: ...lues 35 13 10 Changing the Air Intake Filter 35 13 11 Transmission Belts 36 13 12 Checking Transmission Belts 36 13 13 Changing Transmission Belts 36 13 14 Changing Air Filtration Cartridges 37 13 15 Temperature Effect on Filter Life 39 13 16 Condensate Discharge 39 13 17 Changing Flex Hoses 40 13 18 Safety Valves 40 14 0 Power Requirements 41 14 1 Amperage System Load 41 14 2 Rotation Check 41 15...

Page 6: ...der heavy duty conditions 43 17 4 Nuvair Customer Care Contact 44 18 0 Spare Parts List 44 19 0 Service Log 45 20 0 Appendix 46 20 1 Supply and Breathing Air Specifications 46 20 2 Filter Element Life Factors 46 21 0 Nuvair Compressor System Warranty 47 22 0 PLC Wiring Schematics 49 Separate Manuals Included Compressor Parts Manual ...

Page 7: ...ure 14 Illustration of proper positioning 24 Figure 15 Air extension connection diagram 25 Figure 16 Safety valve example 26 Figure 17 Oil interstage and final pressure gauges 27 Figure 18 PRESEC Filter Control 28 Figure 19 Tank refill illustration DIN valve pictured 30 Figure 20 Opening drain valve depressurizes system 30 Figure 21 Oil level viewer 33 Figure 22 Checking and changing lubricating o...

Page 8: ...ion operation or maintenance information which is important but not hazard related 1 1 Required Operator Training This manual must be read carefully and in its entirety All compressor operators maintenance personnel must read this entire manual with due care and attention and observe the instructions information contained herein Company owners ensure that the operator has the required training for...

Page 9: ... attention 4 You must have a detailed understanding of where and how the compressor is to be used 5 Before starting work make sure that safety devices are working properly and that their use is understood in the event of any doubts do not use the compressor 6 Observe the warnings given in this manual with due care and attention 7 Constant and careful preventive maintenance will always ensure a hig...

Page 10: ...as free from dust risk of explosion corrosion and fire Improper use could have serious consequences for the user Do not disconnect the hose from the fittings or the clamp when under pressure Change the air purification filters regularly as described in section 13 0 Drain the condensate regularly as illustrated in section 13 2 Condensate Discharge The power must be disconnected and locked out befor...

Page 11: ...be held liable for breakdowns problems or accidents caused by failure to observe this rule Check that the fittings provide a proper seal by wetting them with soapy water Stop the compressor and eliminate any leaks immediately when detected Do not attempt to repair high pressure tubes by welding them or while the compressor is running Do not empty storage tanks completely not even for long term sto...

Page 12: ...sure maintaining valve PMV setting of about 2000 psi 138 bar After the first 25 hours carry out in addition to the scheduled maintenance the following tasks Change the compressor oil Change the oil filter Check and adjust nuts and bolts When changing the oil filter inspect the filter element and check for any deposits If metal or carbon deposits are present locate the source before restarting the ...

Page 13: ... bare metal of the motor frame or other suitable means 4 Protect all power cables from contacting sharp objects Do not kink power cables and never allow the cables to contact oil grease hot surfaces or chemicals 5 Make certain that power source conforms to the requirements of your equipment 6 Pull main electrical disconnect switch and disconnect any separate control lines if used before attempting...

Page 14: ...t mean to imply that the preceding list of Safety and Operation Precautions is all inclusive and further that the observance of this list will prevent all injuries or equipment damage 2 2 High Risk Areas of Compressor Some areas of the compressor pose a level of operator bystander risk that were not possible to eliminate at the design stage or for which safeguards could not be provided without com...

Page 15: ... www Nuvair com Figure 2 The Nuvair MCH36 Silent Touch Compressor 3 0 Compressor Layout Oil Pressure Gauge 1 Interstage Pressure Gauges 4 Fill Pressure Gauge 1 HP Air Outlets 4 Emergency Stop Cabinet Temperature Touchscreen HMI Display ...

Page 16: ...nternal pressure drops below 600 psi of the pressure setpoint 5 If SINGLE FILL MODE is displayed in the in the upper left corner Figure 3 the compressor will not restart If AUTO RESTART MODE is displayed the compressor will automatically restart when the internal pressure drops 6 Press the green START button to start the compressor 7 Press the red STOP button to stop the compressor at any time 8 A...

Page 17: ...ired To access secured settings enter the digit security code in the security code input screen Figure 5 4 3 Alarm History Screen This page is a record of alarm or service events Figure 6 The alarm event type will be noted when the alarm activated and when the user clears or deactivates the alarm Service events will record the date it was reset 4 4 Service Hours Screen This screen shows non resett...

Page 18: ...IHI These alarms and others are further described in Section 4 7 On the following pages are expanded descriptions of Dashboard functions and alarm states 4 7 Alarm Events and Descriptions The MCH36 Silent Touch dashboard has 55 different alarm states Each alarm condition has a unique name and associated definition Alarm names and definitions are factory set When an alarm event threshold is reached...

Page 19: ...GE PSI HI The third stage temperature is high and requires evaluation Alarm sounds 3RD STAGE PSI HIHI The third stage pressure is critically high The system shuts down immediately and sounds an alarm 3RD STAGE PSI LO The third stage pressure is low and requires evaluation Alarm sounds 3RD STAGE PSI LOLO The third stage pressure is critically low The system shuts down immediately and sounds an alar...

Page 20: ...FILTER CAN Inspection of high pressure filter canister required Alarm sounds INSPECT INTAKE FILTER Inspection of intake filter required Replace as needed Alarm sounds INTAKE FILTER CHANGE Replacement of intake filter required Alarm sounds INTAKE FILTER INSP RESET Inspection of intake filter alarm has been reset INTAKE FILTER REPLACE RS Replacement of intake alarm has been reset LO OIL LEVEL ALM Th...

Page 21: ...t alarm has been reset REPLACE HP FILTER CAN Replacement of high pressure filter canister required Alarm sounds REPLACE HP FLEX HOSE RS High pressure flex hose replacement alarm has been reset REPLACE HP FLEX HOSES Replacement of high pressure flex hoses required Alarm sounds REPLACE INTERSTAGE TUBE R Replacement of interstage cooler tubes alarm has been reset REPLACE INTERSTAGE TUBES Replacement ...

Page 22: ... having first read the instruction manual supplied with the machine and observed the instructions The user shall pay all necessary attention and adopt appropriate control devices safety and protection for vessels which have indicated on the test certificate maximum working pressure lower than that indicated on compressor 2 Condensate discharge information label Indicates position of condensate dis...

Page 23: ...ssure Gauges 3 Condensate Separators on Each Compressor Stainless Steel Interstage Cooling Tubes Low Pressure Oil Pump with Filter Oil Level Sight Gauge and Oil Pressure Gauge Automatic Condensate Drains Loadless Start Low Oil Shutdown Switch Final Stage Head High Temperature Switch set at 350 F PRESEC Visual Filter Element Moisture Indicator System 2 CAN 35 Filtration Towers o 60 000 cu ft Alumin...

Page 24: ...cent walls and inches 59 inches 1 5 m from ceiling Figure 14 Select a location where ambient room temperature complies with stated requirements Make sure the installation space is well ventilated 8 2 Air Intake Extension Connection If the compressor is installed in an area without the necessary ventilation requisites described in section 8 1 it will be necessary to install an air intake extension ...

Page 25: ...ctrician doing the install determines the plug necessary An efficient compressor grounding system is an essential compressor safety requisite Make sure your electrician follows approved and compliant standards for your location 9 0 Checks for the Start of Each Working Day Inspect the exterior of the compressor couplings pipes pneumatic components etc and check for any oil leaks Replace parts where...

Page 26: ...ury to personnel and renders the warranty null and void Should the safety valve fail to work properly contact Nuvair Technical Support 9 4 Storing Technical Documentation The use and maintenance manual and its appendices must be stored carefully and must always be kept where they can be accessed easily for immediate review This Operation Manual contains important safety information and should alwa...

Page 27: ...sure inside the first compression stage 2nd Stage This gauge indicates the pressure inside the second compression stage 3rd Stage This gauge indicates the pressure inside the third compression stage Fill Pressure This gauge indicates the pressure as it exits the compressor If the pressure fails to reach the pressure switch set pressure switch off the compressor and contact Nuvair 10 2 Cabinet Temp...

Page 28: ... determining the source of the alarm While the yellow light pulses b the steady green light a will illuminate because the filter element is not completely saturated If no LEDs illuminate the PRESEC is not powered or has another type of electrical fault Note Filter element saturation occurs when a filter element can no longer absorb sufficient water vapor to produce air gas that complies with recog...

Page 29: ...ident signs of internal or external corrosion do not refill them even if they have been tested Use only tested tanks as proven by a test stamp and or certificate The working and tank refill pressures are stamped on the tanks themselves It is forbidden to refill them at a pressure greater than that indicated Different fill valves are available at the time of purchase Variations include INT Yoke DIN...

Page 30: ...ce instructions with extreme diligence It is thus advisable to read the information below and consult the manual every time an inconvenience arises For further information please contact Nuvair Phone 1 805 815 4044 Email info Nuvair com Do not carry out these tasks if the compressor has just shut down and is hot wait for the compressor to cool All maintenance work must be carried out with the comp...

Page 31: ...ne after some years of use If substantial modifications are made the manufacturer cannot be held liable for any dangers that might arise This work must be carried out by a Nuvair approved mechanic 13 4 Scheduled Maintenance Table Maintenance interval times are for typical use and may vary based on the conditions under which the compressor is used Before Every Use Hours Hourly Maintenance 5 25 50 1...

Page 32: ...rload of another stage Poor Ventilation Check direction of rotation Clean cooling tubes Contact technical support Contact technical support 13 6 Checking and Changing the Lubricating Oil Filter During the compressor initial break in period the original oil filter and lubricating oil must be changed at the 25 hour runtime mark After the initial change of lubricants and filter the oil and oil filter...

Page 33: ...the maximum shown on the oil level viewer Figure 21 and Figure 22 If the oil level is above the maximum level Position a receptacle under the drain hose Figure 23 so that the oil flows into the exhausted oil receptacle Open the drain valve a Figure 22 and let the oil flow out until the oil level returns within the maximum and minimum limits Close the drain valve If the oil level is below the minim...

Page 34: ...en the top plug b Figure 22 Remove the plug i Figure 22 open the tap a and drain all the oil Unscrew the filter c Figure 22 being sure to recover the oil inside it Replace the filter c with a new one Wet the gasket g Figure 22 of the filter with a little oil and firmly tighten the filter manually Close the drain valve a Remove the top up plug b Fill the oil sump with 3 5 L 0 92 gal of oil from top...

Page 35: ...te the filter cartridge inside the filter housing 90 every 50 hours Change the air filter by following these steps as illustrated in Figure 25 Open clips c and remove the air filter cover a Remove the air filter cartridge b Replace the cartridge with a new one Replace the O ring see d Figure 24 with a new one Reclose the cover a and close the clips c Do not carry out these tasks if the compressor ...

Page 36: ...eplaced 13 13 Changing Transmission Belts To replace the transmission belts proceed as follows see Figure 27 Insert a screwdriver a between the first belt b and the pulley c of the cooling fan d Rotate the fan d counterclockwise until the belt comes out of the pulley groove Repeat the procedure on the second belt Change the belts with new ones Make sure the belt model and length are the same Check...

Page 37: ... section 20 2 for details on filter element life factors If the compressor is used in an environment where CO carbon monoxide or exhaust fumes may be present a special tri chemical filter element containing a CO catalyst must be used and can be supplied on request Shut down the compressor system Open and leave open the drain valve Figure 20 to vent all pressure from the circuit Use the wrench a Fi...

Page 38: ...tem prior to opening any filtration canister Failure to vent pressure from the system prior to opening the canister can lead to serious personal injury or death Difficulty turning the filter cap may indicate there still is pressure in the filter canister If the compressor is in an area where there is high humidity and high heat the life of all filtration elements may be as little as 35 of rated op...

Page 39: ...t be drained every 5 10 minutes of operation The Dashboard operates the condensate discharge auto drain automatically Users can set the auto drain timer in the Dashboard The yellow TEST PURGE button Figure 3 page 16 should be pressed every day to make sure that the auto drain is working properly The condensate is collected in a tank Figure 30 periodically check this tank to prevent overfill and co...

Page 40: ... whipping When the tanks are being refilled unauthorized personnel must remain at a distance of at least 3 meters 10 feet It is strictly forbidden to disconnect the hoses from the fittings or refill valve when the machine is under pressure To change the tank refill hoses proceed as follows Disconnect the bottle refill hoses by unscrewing the fittings 17 mm wrench Replace the old hoses with new one...

Page 41: ... manual when working on the compressor system the main breaker at the power source must be locked out in the off position 14 1 Amperage System Load Voltage Phases Hertz Amperage Horsepower Kilowatts 208 230 3 60 48 20 15 380 415 3 50 29 20 15 440 480 3 60 25 20 15 14 2 Rotation Check Always turn on bump starter and run motor very briefly to check for proper direction of rotation A sticker Figure 3...

Page 42: ...achine parts During machine downtimes it is advisable to run the compressor for 20 minutes every 15 days 15 3 Dismantling and Putting the Compressor Out of Service Should you decide not to use the compressor or any of its parts any longer you must precede with its dismantling and putting it out of service These tasks must be carried out in compliance with the standards in force Should the compress...

Page 43: ...vant standards in force Contact the fire department 17 0 Maintenance Register 17 1 Customer Service Customers continue to receive assistance after the purchase of a compressor To this end Nuvair has created a customer service network covering the entire country 17 2 Scheduled Maintenance The scheduled maintenance program is designed to keep your compressor in perfect working order Some simple task...

Page 44: ...Parts List Compressor System Components Type Part Number Compressor Lubricant Food Grade nitrox compatible Nuvair 455 1 gal 9406 Compressor Lubricant Industrial Grade Nuvair 751 1 gal 9403 High Pressure Air Filter Elements Drying Filter Cartridge NUV65677 Breathing Air Filter Cartridge NUV65247 Air Intake Filter Element 36 05 0504 Oil Filter Spin On SC000688 Transmission Belt A90 ...

Page 45: ...MCH36 Silent Touch Nuvair Page 45 www Nuvair com 19 0 Service Log Date Technician Name Service Performed ...

Page 46: ... system must contain 0 003 PPM oil vapor All breathing nitrox produced for diving must be purified to meet these same requirements except for oxygen content Nitrox oxygen content must measure within 1 O2 of the specified value of the mixture using a properly calibrated oxygen analyzer i e nitrox produced with a target content of 32 O2 must measure in the range of 31 33 O2 Periodic air quality test...

Page 47: ...them are considered expendable and are not covered under the terms of this policy This includes maintenance and consumable items listed as part of a suggested maintenance program included with system documentation Return Policy Application for warranty service can be made by contacting Nuvair during regular business hours and requesting a Return Material Authorization RMA number Materials that are...

Page 48: ... to Nuvair This card is to establish registration for any necessary warranty work and as a means of communication that allows Nuvair to contact the user regarding this product The user must notify Nuvair of any change of address by the user or sale of the product All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to date Change Date Descriptio...

Page 49: ...MCH36 Silent Touch Nuvair Page 49 www Nuvair com 22 0 PLC Wiring Schematics PLC wiring schematics on the following pages ...

Page 50: ... KML 1 3 5 2 4 6 95 96 97 98 FR1 M 3 1 2 5 4 3 6 FU1 RSF 100VA TC1 0 N 13 0 Neutral L3 L2 L1 Ground 1A Class CC Delay Acting FU2 1A Class CC Delay Acting Ground 14 12 11 Sequential Phase Relay Ground 1 3 5 2 4 6 M1 M3 M2 Optional Cabinet Cooling Fan 0 Common 24V XMFR 120 VA TC2 FU3 2A Time Delay FU4 2A Time Delay ...

Page 51: ...ral 0 0 N Neutral 95 96 FR1 Presec Cabinet Temp Emergency 21 22 A1 A1 A1 A2 A2 A2 KML KMD KMY R1 R2 R3 R4 11 11 11 11 14 14 14 14 12 12 12 12 13 14 KML A2 KMF A1 A1 A2 ADS Primary Contactor Delta Contactor Wye Contactor AutoDrain Solenoid Cooling Fan Contactor ...

Page 52: ... Switch Overload Phase Sequence Presec Filter Low Oil Aux 1 Aux 2 Aux 3 Condensate 24VDC Spare Spare Spare Spare Spare Spare Spare C3 X3 C3 X4 C3 C2 C3 X5 C3 X6 C3 X7 C3 X8 Emergency Stop on Panel Cabinet Temp Switch on Panel Motor Overload on Contactor KML Phase Sequencing RSF Presec Filter Monitor on Cabinet Face Low Oil Level Monitor in Compressor Block Auxillary Contact in KML Contactor Auxill...

Page 53: ...uts Common 24VDC FU3 Black Black C0 C3 C0 C4 Red Red Red Red Black Black Black Black C0 Y1 C0 Y2 C0 Y3 C0 Y4 C0 Y5 C0 Y6 Spare Spare R1 R2 R3 R4 KML Primary Contactor Relay KMD Secondary Contactor Relay KMY Start Contactor ADS Autodrain Solenoid Relay Card 0 ...

Page 54: ... 0V 0V 0V 24V CH1 CH2 CH3 CH4 Gnd Gnd Gnd Gnd SHD SHD SHD SHD 24VDC FU3 Common 0V 0V 0V 0V 0V 0V 24V CH1 CH2 CH3 CH4 Gnd SHD 1 st Stage Pressure 2 nd Stage Pressure 3 rd Stage Pressure 4 th Stage Pressure Final Fill Pressure 0 8000 Psi 0 8000 Psi 0 500 Psi 0 1500 PSI 0 100 Psi ...

Page 55: ...F 1 Ea Fan Contactor Fuji Electric SC 02 220VAC FU1 1 Ea 3 Phase Class CC Fuse Holder Siemens 3NW75330HG FU2 1 Ea 1 Phase Class CC Fuse Holder Siemens 3NW75130HG R1 1 Ea 24 Volt Relay Allen Bradley 700 HLT1Z 24 R2 1 Ea 24 Volt Relay Allen Bradley 700 HLT1Z 24 R3 1 Ea 24 Volt Relay Allen Bradley 700 HLT1Z 24 R4 1 Ea 24 Volt Relay Allen Bradley 700 HLT1Z 24 HMI 1 Ea 10 Inch HMI Display Automation Di...

Page 56: ...MCH36 Silent Touch Nuvair Phone 1 805 815 4044 Fax 1 805 486 0900 Address 1600 Beacon Place Oxnard CA 93033 USA Email info nuvair com Website www Nuvair com Rev 05 2021 SKU 8044 PLC ...

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