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Curtis-Toledo Rotary Compressor

CAP862

Operations and Maintenance Manual

Chapter 7 Page 2

Compressor will not load

a.  Pressure switch set too low
b.  Inlet valve will not open.
c.  Faulty solenoid valve.

Capacity (delivery) is below stated amount

Restricted inlet air filter.

Inlet valve partially closed.

Air pressure set too high.

Insufficient oil flow.

Solenoid valve malfunction.

Belt slippage.

Leakage in air system.

Worn air end.

Compressor surges

Erratic air demand.

Customer air system too small for demands.

Faulty minimum pressure valve.

Pressure switch differential too low for the
system conditions.

Loose electrical connection between the
controller and the solenoid valve.

Faulty pressure transducer.

Faulty solenoid valve.

Faulty pressure relief valve.

Excessive Oil Consumption

Overfilled sump.

Broken oil line.

Plugged oil return line.

Operating below rated pressure.

Damaged or dirty separator.

Lightly loaded or excessive load/unload
cycles.

Using incorrect oil.

Содержание SE Series

Страница 1: ...WARNING WARNING WARNING Personal injury and or equipment damage will result by failing to pay attention to the vital safety information and instructions in this manual Carefully read understand and retain all safety information and instructions before operating this compressor OPERATOR S MANUAL SE Series Belt Driven Rotary Screw Compressors SE20 SE25 SE30 SE40 SE50 ...

Страница 2: ...ARNING WARNING WARNING WHEN DISCONNECTING POWER FROM THE UNIT POWER MUST BE OFF FOR A MINIMUM OF 15 SECONDS OR AN ERROR CODE MAY BE DISPLAYED ON THE CONTROLLER TO CLEAR AN ERROR CODE REFERENCE CONTROLLER MANUAL ...

Страница 3: ...4 6 SE 50 Specifications 4 7 Protection Warning 4 8 Control Systems Electrical Circuit 4 9 5 0 Operation Inspection 5 1 Storage 5 2 6 0 Maintenance Maintenance Intervals 6 1 Air Filter Oil Filter 6 2 Air Oil Separator 6 3 Lubricant 6 4 Oil Analysis 6 5 Thermostatic Minimum Pressure Valves 6 6 Belts 6 7 Sheave 6 8 Fan Motor 6 9 Bearings 6 10 Air end Motor Removal 6 11 Recommended Maintenance Time I...

Страница 4: ...is not understood or familiarized Alert signals Description of signals Danger Danger is used to indicate presence of a hazard that will cause severe personal injury or 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 whi...

Страница 5: ...ines If the labels are not clear or missing please contact CURTIS directly Explanations of safety symbols Operation manual Follow the instructions before use of this compressor Confirm the direction of rotation before startup 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 please contact CURT...

Страница 6: ... Rotary Compressor CAP862 Operations and Maintenance Manual Chapter 1 Page 3 Danger Electric circuits Danger Rotating parts Danger Hot or noxious gases outlet unbreathable Danger Heat Do not touch hot areas Rotation ...

Страница 7: ... Turn off power supply before maintenance or operating around electric equipment such as starter and motor Remove the 4 bolts that secure the air end motor sub frame to the enclosure before test run or startup DO NOT loosen the bolts that go though the isolators Please contact CURTIS or distributor for assistance if necessary ...

Страница 8: ...afety 1 Become familiar with this manual and follow the instructions before operating the compressor 2 If any malfunctions or trouble occurs do not run compressor until problem is resolved 3 Make sure the compressor has been disconnected before servicing or changing parts Lockout and tag out prior to maintenance 4 To ensure human safety and protect the facility from damage do NOT ignore electrical...

Страница 9: ...out further treatment Release all pressure from the system prior to maintenance Electric shock could be fatal Grounding of starter and motor is necessary Choose grounding cable according to the power range of the compressor Ground fan motor through starter Lockout and tag out power supply before working on control panel Lockout and tag out power supply before inspection and maintenance compressor ...

Страница 10: ...ling system 1 Air piping 1 Install required accessories 2 Main piping should have 1 2 slope away from compressor to drain the condensate 3 Pressure drop of piping must not exceed 5 of discharge pressure Select larger pipeline than required for better efficiency 4 Branch line must be located at the top side of main pipeline to avoid the condensate from flowing to the facilities 5 To prolong service...

Страница 11: ...nd local codes should do all electrical wiring Be sure to investigate the local requirements before installing the compressor Refer to the wiring diagram before starting any work The power supply should be adequate and free of parasitic loads that will cause an under voltage condition during the operation of the compressor otherwise there will be nuisance electrical shutdowns This equipment requir...

Страница 12: ...Electric Code state code and any local codes in accordance with the wiring diagram specific to your compressor model shown in the included wire diagram Chart of Unit Amp Draw Figure 2 2 Model 200 V 230 V 460 V 575 V SE20 Amp Draw 82 4 71 7 35 9 27 5 SE25 Amp Draw 102 6 89 2 44 6 35 5 SE30 Amp Draw 120 104 2 52 1 41 7 SE40 Amp Draw 156 9 136 68 53 7 SE50 Amp Draw 194 4 168 5 84 25 67 4 Failure to p...

Страница 13: ...f the main rotor and the matching grooves of 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 compressor cycle oil is injected into the compressor for th...

Страница 14: ...ssary The coalesced air then passes through the minimum pressure valve set to maintain a minimum of 65 PSI in the oil separator to ensure a sufficient flow of oil to the compressor The compressed air then enters the aftercooler where it is cooled and discharged to its point of usage A sufficient amount of oil is stored in the oil separator tank and is forced by the pressure of compression from the...

Страница 15: ...ake filter 13 Oil filter 2 Motor 14 Air outlet ball valve 3 Intake valve 15 Oil separator 4 2 way solenoid valve 16 Oil level gauge 5 Pulley air end side 17 Pressure relief valve 6 Pulley motor side 18 Minimum pressure valve 7 Pressure transmitter 19 Water separator optional 8 Air end 20 Drain valve 9 Drain valve 21 Thermostatic valve 10 Oil return check valve 22 Belt 11 Separator tank 23 Fan 12 R...

Страница 16: ...he intake valve is closed and the compressor is running off load 3 Thermal couple Lack of oil in circulation will induce high discharge temperature It will be shown on the panel through the signal from the thermal couple General setting value is 230 F 110 Do not operate over this temperature otherwise compressor trip will occur 4 Separator tank There is an oil gauge on the bottom side of tank Main...

Страница 17: ...pose of oil injection in an oil flooded screw compressor is to dissipate the heat away in the process of air compression 3 Function of parts on the oil flow system A Oil Cooler The function of oil cooler is the same as air cooler Environment is a crucial factor for air cooled type compressor please install unit in a well ventilated area Clean the dust on the fins of radiator periodically with comp...

Страница 18: ...al Chapter 4 Page 4 3 Cooling system Air cooled Air is fed by a fan through the radiator fins and dissipates heat away from the compressed air and oil The highest allowable unit temperature setting is 230 F 110 Any temperature above this will result in compressor shutdown ...

Страница 19: ...0 3 1 100 2 8 90 2 5 80 2 3 Discharge Temp F Ambient temperature 27 Pressure relief valve setting PSIG Setting pressure 200 psi Power hp kw 20 15 25 18 5 Enclosure TEFC Main Motor Speed rpm 1755 1760 Fan Motor Power h p kw 1 0 75 1 0 75 Starter Y Voltage Volt 200 230 460 575V 3PH 60HZ Frequency Hz 60 Length in mm 44 1130 44 1130 Width in mm 33 848 33 848 Height in mm 51 1302 51 1302 Weight lb kg 1...

Страница 20: ...148 4 2 139 3 9 Discharge Temp F Ambient temperature 27 Pressure relief valve setting PSIG Setting pressure 200 psi Power hp kw 30 22 40 30 Type TEFC Main Motor Speed rpm 3530 1770 Fan Motor Power 1 0 75 1 5 1 Starter Y Voltage Volt 200 230 460 575V 3PH Frequency Hz 60 Length in mm 44 1130 52 1330 Width in mm 33 848 39 1000 Height in mm 51 1302 61 1555 Weight lb kg 1345 610 1764 800 Discharge outl...

Страница 21: ... 5 2 170 4 8 Discharge Temp F Ambient temperature 27 Pressure relief valve setting PSIG Setting pressure 200 psi Power hp kw 50 37 Type TEFC Main Motor Speed rpm 1770 Fan Motor Power 1 5 1 Starter Y Voltage Volt 200 230 460 575V 3PH Frequency Hz 60 Length in mm 52 1330 Width in mm 39 1000 Height in mm 61 1555 Weight lb kg 1940 880 Discharge outlet inch 1 PT Oil Capacity Gal l 5 19 System Motor Dim...

Страница 22: ...s during operation please contact manufacturer immediately to prevent damage to the motor 2 Protection for discharge temperature Discharge temperature setting is 230 F 110 If the temperature exceeds 230 F 110 the compressor will trip One of the most common reasons for high discharge temperature is an issue with the oil cooler For an air cooled compressor if the radiator is clogged oil temperature ...

Страница 23: ... relief valve is opened resulting in the intake valve being closed Compressor is then running in off load 4 Stop Pressing the OFF button will lead to an opened solenoid valve and a closed intake valve As a result the air is then discharged into the atmosphere When pressure in the tank reduces to certain value motor will then shutdown 5 Emergency stop When the emergency stop is activated the main p...

Страница 24: ...t correct 6 Press ON to restart the compressor 7 Observe any warning from panel and LED lights 8 Time relay will be activated after pressing the OFF button the motor will stop automatically after 10 15 seconds 9 Compressed air will be released immediately after pressing the OFF button B Inspection before startup In order to protect the compressor and increase operation efficiency it is necessary t...

Страница 25: ...ot wanted in the system 4 Record voltage current discharge pressure discharge temperature oil level and inspect gauges periodically during operation for future reference D Storage In some cases it may be necessary to store the compressor for extended periods of several months before placing the unit in operation When this is required do the following 1 Cover and seal all machine openings to preven...

Страница 26: ...s first check after 50 hrs for proper tensioning Initial 30 days or 500 hours 1 Change oil filter element Every 6 months or 1000 hours 1 Inspect air filter element 2 Check the belts for signs of wear and replace as necessary 3 Clean motor and ventilation openings 4 Take oil sample if applicable 5 Check hoses for signs of wear or deterioration Every 12 months or 2000 hours 1 Change oil filter eleme...

Страница 27: ...Replace the cover and tighten the wingnut 10 Reset 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 ingress...

Страница 28: ...ff the unit disconnect the power and lockout and tag to prevent accidental starting 1 Allow one minute after stopping for the system to settle and the pressure to be relieved 2 Using a strap wrench remove the old element and gasket 3 Clean the gasket surface with a clean rag 4 Apply a light film of oil to the new gasket 5 Hand tighten the new element until the new gasket is seated in the gasket gr...

Страница 29: ...cant more frequently Temperature of operation has the most significant effect on the life of the lubricant The following chart shows the decrease in interval based on temperature Figure 6 1 Discharge Temperature RS8000 Up to 180o F 8000 hrs 180 to 190o F 6000 hrs 190 to 200o F 4000 hrs 200 to 210o F 2000 hrs To eliminate confusion concerning what type of lubricant to use always use Curtis RS8000 L...

Страница 30: ...he fill cap and then remove the fill cap 4 Inspect the cap for damage and cleanliness Replace if necessary 5 The oil should be Visible in the sight class for the SE20 SE30 Arrow in the green section of the gauge placed on the separator tank for the SE40 SE50 6 Replace the cap securely Never put the cap on without tightening it immediately Changing Compressor Lubricant 1 Switch off the unit disconn...

Страница 31: ...element 6 Reassemble with the renewal parts 7 Replace any volume of oil lost with fresh oil Also replace the fill cap if this was used to insure relief of the system pressure 8 Return unit to service 6 8 Minimum Pressure Valve The minimum pressure valve is a non adjustable spring biased check valve It has been designed to maintain a minimum sump pressure of 50 psig If the pressure is allowed to ge...

Страница 32: ... belts 1 Switch off the unit disconnect the power and lockout and tag to prevent accidental restarting 2 Allow one minute after stopping the compressor for settling and the pressure to relieve 3 Remove the belt guard 4 Inspect for any fraying or cracking of the belts If there is any replace the belts 5 Check the tension The deflection should be about 1 64 per inch of span between the sheaves with ...

Страница 33: ...rections is to use an accurate straight edge 1 Switch off the unit disconnect the power and lockout and tag to prevent accidental restarting 2 Allow one minute after stopping the compressor for settling and the pressure to relieve 3 Remove the belt guard 4 Lay the straight edge across the face of the motor sheave and check the alignment with the air end sheave 5 Then lay the straight edge across t...

Страница 34: ...bearing lubrication Bearing 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 ...

Страница 35: ...2 Remove the relief plug and free the hole of hardened grease 3 Add grease with hand operated grease gun until it appears at the shaft hole in the end plate or the relief plug outlet 4 Re connect the power and run the unit for 20 minutes without the relief plug in place 5 Switch off the unit disconnect the power and lockout and tag to prevent accidental restarting 6 Re install the grease relief pl...

Страница 36: ...s when removed I Remove 4 bolts from base of inlet valve assembly and set inlet valve assembly aside J Remove belt guard screen K Loosen 4 bolts for belt adjustment inside of belt guard L Loosen belts using adjusting bolts M Remove belts Measure position of pulleys on air end shaft and motor shaft before removing for proper installation and alignment N Support air end O Remove 2 bolts from oil by ...

Страница 37: ...X X Oil Synthetic RS8000 X Minimum Pressure Valve X Suction valve X Thermo valve X Motor bearing lubrication X X X X Belt X NOTE Oil change intervals shown are for compressor operating temperatures below 200 F 93 C Reduced service periods apply at high temperature and high humidity environments Oil change intervals may vary based on oil sampling results MPV 8000 hours or 1 once per year Suction Va...

Страница 38: ...immediately a Pressure switch or timer failure b Incorrect heaters or adjusted too low in starter c High Air Temperature switch open due to restricted oil flow d Loose or missing electrical components e Pressure switch set too high f Motor overloads trip out g Low voltage Compressor does not build up to the desired pressure a Inlet valve partially closed b Belt slippage c Restricted inlet air clea...

Страница 39: ... Leakage in air system h Worn air end Compressor surges a Erratic air demand b Customer air system too small for demands c Faulty minimum pressure valve d Pressure switch 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 Consumpt...

Страница 40: ...anels are open j 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 switch not set correctly b Inlet valve not closing properl...

Страница 41: ...age 1 8 0 Maintenance Log Model _____________________ Serial umber _____________________ Date Hourmeter Reading Changed Greased Motor Bearings Cleaned Cooler Checked Fitting Tightness Air Filter Oil Filter Oil Separator ...

Страница 42: ...CAP862 Chapter 8 Page 2 OTES ...

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