CAP881 OCTOBER, 2012 REV.A SEG Series OIL-INJECTED ROTARY SCREW COMPRESSORS OPERATOR MANUAL SEG-5 SEG-10 SEG-7.
CAP881 Table of Contents 1.0 Introduction -Preface ………………………………………………………………………….. -Safety …………………………………………………………………………… 3 7 2.0 Receiving and Installation - Installation / Precaution …………………………...…………………………… -Electrical …………………………………..…………………………………… 9 19 3.0 Principle of Screw air compressor - General …...……………………………………………………………..…….. - Air/Oil Flow………………………………………………………………......... 21 22 4.0 System Flow Chart and Components Function - System Flow Chart …………………………………………………………….
CAP881 1.0 Introduction Preface Warning Read this manual before assembly or operation of the compressor. Become familiar with this information, its safety instructions and its operation before starting unit. Serious personal injury may result if safety and/or operational information is not understood or comprehended. ◎ Alert signals Description of signals △ ! Danger is used to indicate presence of a hazard that will cause severe personal injury, death, or substantial property damage.
CAP881 Description of symbols – cont. Symbols Description of symbols Prohibited Extreme caution ◎ Warning Labels are placed on the machines. If the labels are not clear or missing, contact FS CURTIS directly. ◎ Explanations of safety symbols Operation manual Follow the instructions before using this compressor. Confirm the direction of motor rotation before startup. See Section 5.
CAP881 Danger: Electric circuits Danger: Rotating parts Danger: Hot or noxious gas outlet: Not Breathable Danger: Heat.
CAP881 Read instruction Hearing protection required Turn off power supply before maintenance or service around electric equipment, such as starter, and motor. Remove the 2 RED Shipping Brackets that secure the motor/airend to the base frame before test run or startup. Contact FSCURTIS or distributor for assistance if necessary.
CAP881 Safety 1. Become familiar with this manual and follow the instructions before operating the compressor. 2. If any malfunctions or trouble has occurred, do not run compressor until problem is resolved. 3. Make sure the compressor has been disconnected before servicing or changing parts. Lockout and tagout prior to maintenance. 4. To ensure human safety and protect the facility from damage, an electrical ground is necessary. 5. Wear proper apparel during operation.
CAP881 Additional Safety information for Air Compressors Like all power tools, there is danger associated with operating this equipment. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine with extreme caution. If normal safety precautions are overlooked or ignored, serious personal injury may occur.
CAP881 2.0 Receiving and Installation A. Receiving 1. Check that your shipment matches your order. 2. Check for any damage that may have occurred during shipment. B. Installation. In order to ensure proper installation and trouble free operation with minimal maintenance: 1. Select a location where light is adequate enough to operate, maintain, and inspect the compressor. 2. A clean, low relative humidity and well-ventilated area is best for safe operation.
CAP881 C. Precaution for piping foundation and cooling 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 piping than required for better efficiency. (4). Branch line must be located at the top side of main piping to avoid the condensate from flowing to the equipment. (5).
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CAP881 D. Electrical A qualified electrician in compliance with standards and local codes should do all electrical wiring. Be sure to investigate 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 may cause a low voltage condition during the operation of the compressor; otherwise, there may be nuisance electrical shutdowns.
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CAP881 3.0 General Description COMPRESSOR The compressor assembly is an oil flooded positive displacement, single stage, helical screw type unit consisting of two rotors or screws supported axially by roller bearings and enclosed in a housing or stator as depicted in the sectional view Figure 3-1. Figure 3-1 Compressor Assembly In operation, as depicted below in the compression cycle (Ref.
CAP881 AIR/OIL FLOW Air enters the compressor through the air filter and air inlet valve where it is mixed with oil. After compression, the air/oil mixture is discharged into the oil receiver tank. The oil is removed as the air passes through the Air/Oil Separator element.
CAP881 4.0 System flow diagram and components function A. System flow diagram and components function SEG-5 & 7.
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CAP881 B. Description of system flow chart and component function 1. Air flow path (refer to the flow chart for each type) 1.1. After dust is removed by the intake filter, clean air goes through the air inlet valve into the compression chamber and is mixed with oil. The mixture is compressed and delivered into the oil receiver tank, Air/Oil Separator, minimum pressure valve, (and after cooler on SEG-10 & 15 models only). 1.2. Function of parts in the air flow path (1).
CAP881 2. Oil flow path (refer to the flow chart of each type) (1). Description of oil injection flow chart Pressure in the separator pushes oil into the oil cooler and then passes through the oil filter for filtration after being cooled down. Oil flow then goes into compression chamber from the bottom of air end and also goes to the bearing on the discharge side for lubrication.
CAP881 E. Protection and warning 1. Motor overload protection When the Amp draw exceeds the upper limit of the overload relay setting, the unit will shutdown automatically. Re-setting the unit is required prior to the next start. The relay limit has been set by the factory. To maintain normal operation, do not change the limit setting without consulting the factory. If motor overloads during operation, contact manufacturer immediately to prevent damage to the motor. 2.
CAP881 （6）Auto stop over time period If there is no demand for compressed air, the compressor runs in “off load” mode until it stops after a set time period and remains in Stand-by Mode. The compressor starts automatically to meet air demand. There is an AutoStop warning sign displayed on the controller. more than 6 times per hour. The unit should not start This is controlled by AutoStop time setting on AIMS controller. Minimum is setting is 10 minutes, default is 15 minutes. 2.
CAP881 A. Controller Operating Panel LCD DISPLAY START STOP DOWN UP SET RETURN SHIFT/ENTER START Turns the compressor ON STOP Turns the compressor OFF. Compressor stops after preset idle time. SET Password menu access. After the parameters are modified, pressing this key confirms the change of parameter. UP UP-key scrolls to the next display, switches to the next menu or increases parameter value.
CAP881 5.0 A. Operating Procedure Test run: start and stop 1. Connect power, ground cable, and check power supply. 2. Maintain oil level by keeping it visible in the sight glass by the oil fill port on the side of the airend. 3. If the initial start of the unit will be 6 months or longer after delivery, add 0.5 quarts of CurtisLubePlus FSC- 8000 lubricant through air inlet valve and rotate air end manually to prevent compressor damage due to lack of oil. 4. Check cooling system 5.
CAP881 D. Storage In some cases it may be necessary to store the compressor for an extended period of time before placing the unit in operation. When this is required do the following: 1. Cover and seal all machine openings to prevent moisture and dirt from entering the unit. 2. If the storage conditions are below freezing, drain any condensate from the system and the after cooler on SEG-10/15 models. Outdoor storage is not recommended.
CAP881 6.0 Maintenance 6.
CAP881 6.2 Air Filter The air filter is the primary protection of the compressor from harmful dirt being ingested into the oil system. It needs to be inspected weekly for clogging or holes. The period for these inspections is dependent on the environment the machine is in (at least 2000 hours). Element Inspection and Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Switch off the unit; disconnect the power, and lock and tagout to prevent accidental starting.
CAP881 6.4 Air/Oil Separator The air/oil separator should be changed at 4000 hours, once a year, when there is excessive oil vapor in the discharge air, whichever occurs first. Higher temperature operation can cause the element to plug faster. Consistent operation in temperatures over 180oF oil discharge temperature, will require more frequent separator element changes. DANGER Hot oil under pressure will cause severe injury, death, or property damage.
CAP881 6.6 Lubricant Your compressor has been filled and tested with a high quality synthetic compressor lubricant. It has the advantage of extended service life, high temperature operation, and easy start-up when cold, reduced sludge and lacquer buildup, and is completely compatible with all seals, gaskets, and other compressor materials. When operating in severe conditions it will be necessary to change the lubricant more frequently.
CAP881 Checking Oil Level and Adding Compressor Oil 1. 2. 3. 4. Turn off the unit; disconnect the power, and lockout and tagout to prevent accidental restarting. Allow one minute after stopping the compressor for settling and the pressure to relieve. Remove any dirt from around the fill cap, and then remove the fill cap. Inspect the cap for damage and cleanliness. Replace if necessary. 5. The oil should be visible in the window by the oil fill port on the side of the airend. 6. Replace the cap securely.
CAP881 Check the tension. The deflection should be about 1/64” per inch of span between the sheaves with about 4 pounds of force perpendicular to the belt. To change the belts: (SEG-5 thru SEG-15) 1. 2. 3. 4. 5. 6. 7. Turn off the unit; disconnect the power, and lockout and tagout to prevent accidental restarting. Allow one minute after stopping the compressor for settling and the pressure to relieve. Remove the belt guard. Release tension by loosening the 2 tension bolts for the pulley.
CAP881 8. Return the unit to operation. 6.11 Fan Check the fan mounted to the main motor shaft for cracking, bent or loose blades. Make sure that it is securely mounted and tighten the mounting screws if loose. Replace a damaged fan immediately. 6.12 Motor The motor in the air compressor requires routine maintenance. Every 1000 hours of operation or six months, whichever comes first, check that the motor is clean and ventilation openings are clear.
CAP881 Greasing the bearings: Turn off the unit; disconnect the power, and lockout and tagout to prevent accidental restarting. 1. Clean grease fittings. 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.
CAP881 7.0 Troubleshooting Compressor will not start Unit starts – but shuts down immediately Compressor does not build up to the desired pressure. a. No power b. Fuses blown in the control circuit. c. Loose or missing wires or components in the control circuit. d. Incorrect voltage e.g. using 230 volt in a 460 volt system. e. Faulty temperature sensor. f. Pressure in oil separator tank. a. b. c. d. e. f. Pressure transducer or timer failure.
CAP881 Compressor will not load Capacity (delivery) is below stated amount Compressor surges a. Pressure set too low b. Inlet valve will not open. c. Faulty solenoid valve. a. b. c. d. e. f. g. h. 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. a. b. c. d. Erratic air demand. Customer air system too small for supply. Minimum pressure valve.
CAP881 High Temperature Shutdown High power consumption Safety valve discharges a. b. c. d. e. f. g. h. i. j. Elevated ambient temperature. Low sump oil level. Plugged oil filter. Restricted cooling airflow. Clogged heat exchanger. Thermal bypass is leaking Faulty high air temperature sensor. Delivery pressure set too high. Panels are open. Exhaust air is restricted. a. b. c. d. e. f. g. h. i. Plugged separator. Plugged aftercooler. Improper air pressure switch setting. Too low of a line voltage.
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