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8 | Maintenance, cleaning and repairs

Spectron Gas Control Systems GmbH

44

GES_FS4_0520

8 Maintenance, cleaning and repairs

8.1 General information on maintenance

 DANGER

Voltage

The components of the control and the connections are under voltage. There is a danger of
death on contact.

a) Only allow work in which the control unit must be opened to be carried out by trained spe-

cialist personnel (electricians).

b) Only perform work in which the control unit must be opened when the power supply is

switched off.

c) The five safety rules according to DIN VDE 0105 are to be observed:

ð

Disconnect from the mains

ð

Secure against reconnection

ð

Verify that the system is dead

ð

Carry out earthing and short circuiting

ð

Provide protection from adjacent live parts

 WARNING

Noise emission

When working on pressurised pneumatic supply, significant noise emission can occur. Acute
and chronic loss of hearing may result.

a) Never perform work on the pressurised pneumatic supply without hearing protection.

b) Only replace the silencers when the supply is unpressurised.

 WARNING

Displacement of atmospheric oxygen

In the event of inert gas leaks, displacement of atmospheric oxygen may occur. Danger of suf-
focation!

a) The operator must ensure adequate ventilation and airing in all rooms with gas installations

and monitor the oxygen content.

Correctly performed and timely maintenance increases the service life, ensures availability and
helps to avoid undesirable downtimes.

Servicing and maintenance measures are only permitted to be carried out by competent spe-
cialist companies and persons (electrical engineers).

Maintenance work should be documented by the operator. The documentation should indicate
who carried out which work and when (proof of maintenance).

It is only permitted to use original spare parts or equivalent spare parts as well as suitable tools:

– The recommended maintenance and test intervals are to be observed! (Also observe the

manufacturer's documents)

– The causes of possible defects are to be investigated, e.g. damage, unusual noises, over-

heating, etc.

Содержание FS4

Страница 1: ...User manual Controller FS4 05 2020 ...

Страница 2: ...onal description 13 4 3 Technical data 14 4 4 Boundaries and interfaces 14 5 Installation 15 5 1 General information 15 5 2 Electrical connection 15 5 2 1 Digital inputs 16 5 2 2 Analogue inputs 17 5 2 3 Relay outputs 17 5 3 Pneumatic connection 18 6 Commissioning 20 6 1 Preparations for commissioning 20 6 2 Procedure for commissioning 20 7 Operation 21 7 1 General information on operation 21 7 2 ...

Страница 3: ... 8 Decommissioning 43 8 Maintenance cleaning and repairs 44 8 1 General information on maintenance 44 8 2 Regular maintenance work and cleaning 45 9 Repair 46 9 1 General information on repair work 46 9 2 Troubleshooting and fault rectification 47 10 Dismantling and disposal 48 10 1 General information on dismantling 48 10 2 Disposal 49 ...

Страница 4: ... against misuse It is intended for the qualified personnel and the operator of the facility WARNING Incorrect operation Incorrect operation of the system e g due to instruction errors can lead to personal injury or damage to the system a Access to the user manual by the operating and maintenance personnel must be absolutely ensured at all times b A copy of the system documentation including the us...

Страница 5: ...ng to EU Directive 2014 34 EU may not be used in an explosion hazard zone Furthermore the following operating conditions are regarded as misuse Use for gases in their liquid phase Failure to carry out inspection and maintenance work Pressurisation in reverse opposite to the flow direction Operation with gases that are not specified on the label Operation outside the permissible technical limit val...

Страница 6: ...of Machinery DIN EN 60204 1 Safety of Machinery Electrical equipment of machines Part 1 General requirements regu lates general specifications and recommenda tions as a sub standard of EN 60204 Safety of Machinery Various additional laws regulations and guidelines must be complied with when handling pres surised gases Find out about the laws regulations and guidelines that apply in your location B...

Страница 7: ...o the system which result in a change in function b It is not possible to outline and cover in this manual all hazards arising from the environment or unforeseeable operating conditions of the system In the Safety Instructions chapter Users are informed regarding hazards residual risks and measures for risk reduction The presentation of the safety instructions and the symbols is explained Basic sa...

Страница 8: ...mpliance with all chapters of the user manual b Environmental protection laws and safety regulations must be observed WARNING Maintenance Due to a fault condition e g due to insufficient maintenance parts of the product can be unex pectedly energised This may result in electric shocks a The electrical installation is to be tested regularly Loose connections and defective cables must be rectified i...

Страница 9: ...change in function The system may not be tampered with or modified b Before each repair the system must be depressurised and flushed through c Repairs are only permitted to be carried out by trained persons WARNING Working on the product If an accident occurs when working on the product there is a considerable risk of injury a Never work on the product unattended or unannounced b Observe the site ...

Страница 10: ...handling gases all specifications from the safety data sheets must be followed Local emergency services should be informed of the gases used at the site of the system In the event of mechanical damage the product must be put into a safe operating condition 3 3 1 Emergency stop emergency shut off When the emergency stop is actuated all valves are closed and the power supply to the solen oid valves ...

Страница 11: ... maintain the equipment Persons who do not meet this requirement e g visitors must not remain alone in the overall system Operating personnel must use appropriate personal protective equipment for the activities to be performed and the associated environmental hazards The operational instructions and the spe cifications of the employers liability insurance associations and the safety data sheets m...

Страница 12: ... as necessary When one of the two shutdown options is activated all valves are closed and the power supply to the solen oid valves is interrupted For the operating firm there are 10 digital inputs NC or NC contacts as well as 8 analogue in puts 4 20mA available for the FS4 controller There is also a voltage free relay output for re porting the valve status The connection to all input and output de...

Страница 13: ...s uninterrupted gas supply This can be carried out using valves located before or after the pressure regulating unit The second program is intended for 1 independent supply system which has 2 gas sources that switch over automatically when one side is empty This ensures uninterrupted gas supply This can be carried out using valves located before or after the pressure regulating unit In addition 2 ...

Страница 14: ... and the gas type are given on the identification or la bel 4 4 Boundaries and interfaces The scope of supply includes the product as described in the Design chapter The transfer points to the control air and power supply are the connections on the controller The following areas and functions have not been included in the scope of supply from Spectron other systems lines and installations of the o...

Страница 15: ...the IP65 rating The data sheet and the dimensional drawing are stored in the manufacturer s documentation 5 2 Electrical connection DANGER Voltage The components of the control and the connections are under voltage There is a danger of death on contact a Only allow work in which the control unit must be opened to be carried out by trained spe cialist personnel electricians b Only perform work in w...

Страница 16: ... use of the digital inputs is described in the corresponding instruc tion manuals All sensors must be connected with a two wire cable This cable max diameter 6 mm is passed through one of the cable glands on the base of the unit and connected according to the electrical connection diagrams The polarity of the sensors must be checked before connection A short circuit when connecting a sensor result...

Страница 17: ...le The positive terminal of the signal transmitter is connected to one of the 8 available 24V fuse terminals Each terminal is secured with a 32mA glass fuse 20 x 5 mm All sensors must be disposed of professionally as hazardous waste This cable max diameter 6 mm is passed through one of the cable glands on the base of the unit and connected accord ing to the electrical connection diagrams 5 2 3 Rel...

Страница 18: ...us reactions in the system Incorrect use poses considerable risks to operating person nel and the environment a Only use the product for gases for which it was designed b Only use the product in the specified limit values for pressure and withdrawal quantity c Usage for another type of gas or outside the limit values is prohibited and constitutes mis use WARNING Noise emission When working on pres...

Страница 19: ...t cross contamination of the control air line is prevented The solenoid valves require a supply of clean dry air or nitrogen filtered to 10μm at max 5 5 bar This is connected via a 4mm push in fitting on the base of the device as indicated on the la bel Any exhaust from the solenoid valves is vented internally and excess pressure build up is vented to atmosphere via an IP65 breather on the base of...

Страница 20: ...nnections inside the housing must be checked before commissioning The controller must not be operated without a fuse loose connections must be tightened before commissioning Make sure that the assembly has been correctly carried out the controller is connected to the correct control air the control air supply is in operation and a pressure test for the control air has been per formed the circuit b...

Страница 21: ...vel 1 Level 2 Horn shutdown yes yes yes View analogue inputs yes yes yes View alarms yes yes yes Enable manual shutdown no yes yes Enable service mode no no yes Enable manual control no no yes Acknowledge alarms no yes yes Enter configuration no no yes Table 1 Access data matrix 7 2 Configuration On power up the following screen will be displayed Pressing the flag sets the system language If neces...

Страница 22: ...hed on again it is restarted with the custom user settings Default overview when first switched on without adaptation to customer requirements To configure the system first press Log in After that the keyboard for entering the password is displayed The factory set password is 1111 This gives you level 2 system access rights In the User management 24 menu you can change the user and password settin...

Страница 23: ... password Pressing Log out logs out the user and removes the associated system ac cess rights 15 minutes after logging in the user will be logged out automatically Press Configure to display the configuration menu 7 2 1 Language options Pressing Language takes you to the selection menu for the available languages If necessary other language libraries can be added ...

Страница 24: ...ess levels Pressing the name or password displays a keyboard for data entry A maximum of 16 charac ters for the long name can be entered for each user PIN numbers from 0001 to 9999 can be entered as passwords NOTICE If the system is to be reset to the factory settings all passwords must be set to 0000 and the system must then be restarted ...

Страница 25: ...ves valves 3 and 4 4 independent valves To change the system configurations press the displayed system configuration This allows you to scroll through the three options The switching logic can be set for each system with an automatic changeover The figure below shows that both valves are open simultaneously when switched for 2 seconds The time can be set by pressing the time displayed The keyboard...

Страница 26: ...ngeover overlap press the logic icon This switches between the two available overlap options both valves open both valves closed Overlap time both sides closed for 2 seconds If individual valves are enabled they can be disabled by pressing Enabled They are then hid den in the default overview ...

Страница 27: ...tion 7 GES_FS4_0520 27 7 2 4 Real Time Clock The real time clock can be accessed via the configuration menu The real time clock ensures that all displayed error states are marked with the correct date and time The time is set via this screen ...

Страница 28: ...ress the name of an analogue input to change it min is used to select the minimum sensor value Selecting min 1 automatically sets the pressure unit bar 14 5 will automatically set the pressure unit psi 0 can select the units bar psi kg lbs max is used to select the maximum sensor value ...

Страница 29: ...n all analogue inputs are automatically numbered Pressing one number scrolls to the next analogue input which means that multiple alarm configurations can be assigned to one input for example The analogue inputs that are to trigger an alarm must be switched from OFF to ON The condi tions for alarm triggering and the alarm designations displayed when activated can then be set A single analogue inpu...

Страница 30: ...s 2LS U The channel is active and an alarm is triggered on the 2nd changeover sys tem on the left hand side The gas source is changed over from the left to the right hand side in this process 2RS U The channel is active and an alarm is triggered on the 2nd changeover sys tem on the right hand side The gas source is changed over from the right to the left hand side in this process Table 2 Alarm act...

Страница 31: ...t to change it The status normally open NO or normally closed NC as well as the desired delay can be set Pressing Next will take you to the digital alarm configuration The digital inputs that are to trigger an alarm must be switched from OFF to ON The alarm des ignations displayed when activated can then be assigned ...

Страница 32: ...s Press No action to scroll to the required alarm action These are the possible settings for alarm actions see analogue inputs The settings of the first 3 digital inputs have been configured on the following screen so that all valves are closed in an alarm situation To shut off the valves designations V1 V2 V3 and V4 must be pressed Alarm input 4 is purely a warning alarm ...

Страница 33: ...iguration menu to change the names of the valves in the de fault overview 7 2 8 Assignment of the analogue inputs Analogue values can be displayed in the default overview To do this select Analogue Display in the configuration menu To assign these values to the display press the 0 key in the required display enough times for the number matches the required analogue value ...

Страница 34: ...should also come from a scale If an assignment is set to 0 the corresponding range in the default overview remains empty Pressing OK will take you back to the configuration menu Pressing Overview Screen in the configuration menu to view the assigned displays 7 2 9 Tare setting In the configuration menu press Set Tare Weight to enter the tare weight On this screen you can enter the tare weight of t...

Страница 35: ...the cylinder content is output as a display value This value is used to trigger alarm actions 7 3 Commissioning a valve If all valves are closed and there are no active errors the valve status is displayed as Out of service Pressing the Out of service status display for valve 1 V1L will open a selection window ...

Страница 36: ...FS4_0520 Press the Enabled button to commission the valve 7 4 Putting the valve in standby mode If you click the Out of service status display for valve 2 V1R during an automatic changeover after commissioning the 1st valve a selection window is displayed ...

Страница 37: ...ve 2 is put into standby mode 7 5 Automatic switchover On the following screen the cylinder on valve V1L has triggered an alarm because the set cylin der pressure is has not reached the setpoint value As a result the gas supply in the 1st system has been switched from the left side to the right side according to the set logic ...

Страница 38: ... the alarm are recorded The entries of the resolved alarms must be cancelled to be able to resume operation They can only be cancelled if access is enabled with a level 1 or 2 password After the error has been rectified and the alarm has been cleared the reserve side can be re commissioned See Putting the valve in standby mode 36 ...

Страница 39: ...nfiguration menu Each alarm is automatically cleared from the history after 3 months 7 5 1 Recovery function A Recovery function is integrated into this controller This means that the pressure on the shut down side is monitored for a specified time If the pressure recovers within this time liquefied gases and rises above the set limit value the system is switched back to this side so that it can b...

Страница 40: ...unction for the system for which it is to be activated Enter the value of the pressure increase on which the system is to switch back recovery pres sure automatic changeover pressure pressure increase Enter the time during which the shut off side is to be monitored If system 1 is currently in recovery mode the following screen will be displayed during the mon itoring time 7 6 Manual mode With leve...

Страница 41: ...hutdown and remote shutdown have priority over manual oper ation Pressing the Out of service status display for a valve will open a selection window Press the Manual button to put the valve in manual mode This mode is exited after 15 minutes when the user logs off In this process all valves are closed and manual mode is exited If you press the valve that is in manual mode you will be able to open ...

Страница 42: ...7 Operation Spectron Gas Control Systems GmbH 42 GES_FS4_0520 Selecting YES will open the valve If you touch the opened valve then you can close it again ...

Страница 43: ... configuration menu is used to access the Alarm history All generated alarms are displayed there The alarms already rectified are marked in green Each alarm is stored for 3 months and then deleted automatically 7 8 Decommissioning Switch off the controller by switching the main switch ...

Страница 44: ...rk on the pressurised pneumatic supply without hearing protection b Only replace the silencers when the supply is unpressurised WARNING Displacement of atmospheric oxygen In the event of inert gas leaks displacement of atmospheric oxygen may occur Danger of suf focation a The operator must ensure adequate ventilation and airing in all rooms with gas installations and monitor the oxygen content Cor...

Страница 45: ... which the tests reveal wear or even malfunctions repairs or component re placement must be carried out by competent specialist companies and persons electrical en gineers Components Test Interval Pneumatic components Visual inspection for corrosion damage and correct fastening Functional test Pressure and leakage test At least annually and before each commissioning process Electrical components V...

Страница 46: ...ise emission can occur Acute and chronic loss of hearing may result a Never perform work on the pressurised pneumatic supply without hearing protection b Only replace the silencers when the supply is unpressurised WARNING Displacement of atmospheric oxygen In the event of inert gas leaks displacement of atmospheric oxygen may occur Danger of suf focation a The operator must ensure adequate ventila...

Страница 47: ...No analogue signal Fuse faulty Loose contact on terminal Replace fuse Check terminal assembly Pneumatic valve not switching Loose contact on terminal Pneumatic valve faulty Check terminal assembly Replace pneumatic valve Pneumatic valve leaking Line faulty Valve seal faulty Seal leaking on screw connec tion Replace line Replace valve Replace seal Display not functioning Fuse faulty Supply voltage ...

Страница 48: ... emission can occur Acute and chronic loss of hearing may result a Never perform work on the pressurised pneumatic supply without hearing protection b Only replace the silencers when the supply is unpressurised WARNING Displacement of atmospheric oxygen In the event of inert gas leaks displacement of atmospheric oxygen may occur Danger of suf focation a The operator must ensure adequate ventilatio...

Страница 49: ...trol air supply 4 Pack the control 10 2 Disposal Dismantling and disposal must be carried out in accordance with the official and legal require ments at the site of the system The operator must produce a risk assessment and work instruc tions before dismantling A piece of equipment may only be disposed of when the decontamina tion declaration https www spectron de sites default files 2020 08 Decla...

Страница 50: ...Spectron Gas Control Systems GmbH Fritz Klatte Str 8 D 65933 Frankfurt Tel 49 0 69 38016 0 Fax 49 0 69 38016 200 info spectron de www spectron de ...

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