INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Transcription

1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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3 Alemite Carbon Shield Service Guide 1 1 Alemite Carbon Shield Product Overview Your new Carbon Shield Atomized Oil Lubrication system reflects the most advanced technology for automating the production and distribution of a continuous flow of atomized oil particles for high quality, cost-effective lubrication of gears, chains, rolling element bearings, sleeve bearings, sliding surfaces and other critical machinery components. With its carefully selected components and stainless steel cabinet, every Carbon Shield console is packed with components and features to meet hazardous location requirements in the hydrocarbon industry. The cabinet and the door-mounted touch screen display comply with NEMA 4X Standard. The multi-level password protected Human Machine Interface (HMI) display panel on the Carbon Shield system offers touch access to a unique combination of advanced electronics, diagnostics, monitoring, performance parameters and digital communication interface. Unlike any other system, we have built in intelligence that monitors 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 troubleshooting. Important WARNING and CAUTION notes appear throughout the guide. See the table of contents for detailed information on specific system components and service issues. Potential Hazard Lack of knowledge or experience of this equipment and the hazardous environment in which they operate may result in death, severe injury or serious property damage. Only qualified personnel with proper training and full access to the equipment should perform these procedures. Within the context of this manual, qualified persons are defined as persons who have the skills and knowledge related to the construction and operation of the Carbon Shield equipment and the equipment on which it is installed and who have received safety training to recognize and avoid any hazards involved.

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5 Alemite Carbon Shield Service Guide 3 Fig. 02

6 4 how it functions Oil Mist The Carbon Shield system produces a continuous mixture of air-suspended oil particles in the 1.5 to 5 micron range. Oil is drawn from an integral reservoir (replenished automatically or manually) into the mist head where it is atomized into the air stream. The air/oil mist mixture with a smoke-like consistency then moves through piping at low pressure and low velocity to designated lubrication points on gears, chains, rolling element bearings, sleeve bearings and other key machinery parts. As the mist approaches a lubrication point, reclassifiers special oil mist fittings collect the small dry particles and produce larger wet droplets ideal for the lubrication of bearing surfaces. A unique feature of oil mist lubrication is that carbon particles separate from the oil droplets after they contact the moving bearing component, forming a solid carbon layer on the target warm bearing surfaces. This combination of liquid and solid lubrication layers minimizes metal to metal contact in the bearings. The result is reduced bearing wear. Air Pressure Compressed instrument air from an external air supply enters the console through a filter/regulator. The filter/regulator: Separates any moisture from the air Adjusts to regulate the air to an operating pressure that can be used by the system. A Programmable Logic Controller (PLC) monitors the pressure and relays the pressure signals to the transducer for operational control. Additionally, a gauge on the filter/regulator displays the pressure. Air Temperature The dry, instrument-quality air may be heated by 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 particle temperature and the high speed air atomizes the oil into fine mist resembling smoke. A baffle downstream from the venturi traps the larger oil particles within the spray and returns them to the reservoir. A transducer/regulator and PLC control the mist pressure. The HMI and a pressure gauge(inside the cabinet) provide visual indication of mist pressure. Mist Outlet The fine oil mist particles and air stream move through the mist outlet and distribution piping at very low speed and pressure to various fitting lubrication points on the destination machinery. Mist Density Alemite s Carbon Shield consoles (CSCs) use a proactive approach to mist density monitoring. Unlike current technology, changes in mist density are predicted by CSCs long before an actual change in mist density down the stream can be detected. This prediction is made possible thru the use of software in the PLC, the HMI, and sensors onboard. These devices work together to continuously monitor the set points (not the limits) for all the parameters that influence the oil mist density (a.k.a oil-to-air ratio). When a parameter changes outside its predetermined acceptable range around the set point, an alarm is issued and the potential cause is displayed thru the HMI. Therefore, there is no need for dedicated mist density sensing devices and their inherent operational issues to react to mist density changes.

7 Alemite carbon shield service sheet 5 table of contents 1 Product Overview 1 3 How It Functions 3 Oil Mist Air Pressure Air Temperture Mist Pressure Mist Outlet Table of Contents 4 8 Guide To Illustrations 8 9 System Components and Features 9 9 Electrical System 9 Input Power Cabinet Programmable Logic Controller (PLC) 9 Human Machine Interface PLC Password PLC Inputs/Outputs Mist Head Assembly 11 Oil Mist Outlet Mist Pressure Relief Valve Tank Assembly 12 Loader Fitting Oil Heater Capacitive Level Sensor

8 6 Table of Contents table of contents 12 Air System 12 Air Pressure Control Air Temperature Control Transducer-Booster Assembly Oil Systems 13 Oil Inlet Bulk Oil Storage System Oil Temperature Backup Generator Cabinet Cooler (Optional) Cabinet Purge (Optional) Status Lights Solenoid Valves Installation Site Preparation Systems Connections 17 Air System Connections Inlet Air Oil Inlet Mist Oulet Without Backup With Backup Electrical System 18 Power

9 Alemite carbon shield service sheet 7 table of contents 19 Electrical System (con t) 19 Connections for Remote Global Alarm Connection to Communication Modules Connection to Level Switch in Bulk Storage Tank Drain Connections Operation 20 Before Start-Up Start-Up Sequence Using Change Parameters Feature Using Adaptive Mode Feature Monitoring Function Local Alarm Remote Communication and Alarm 31 Hard Wired Relay General Alarm Signal Internet Based Communicaton Interface to Native DCS Networks PLC Program Loading Switching from Main to Backup Generator Maintenance Checklist Filter Elements 36 Oil Inlet Air Filter/Regulator Oil Inlet Screen Manually Filling Oil Reservoir Loader

10 8 Table of Contents table of contents 37 Troubleshooting Chart Reference Specifications 45 Mechanical Systems Electrical Systems Parts List Wiring Diagrams 49 Fig. 90 PLC Analog Input/Output module wiring Fig. 91 Thermocouple Module Wiring Fig. 92 Relay Wiring Fig. 93 Schematic Diagram References 53 Carbon Shield Nomenclature Fig. 94 General Arrangement Drawing Fig. 95 Installed Arrangement Drawing

11 ALEMITE CARBON SHIELD SERVICE SHEET 9 system components and features The Carbon Shield console consists of separate air, oil and electrical systems that interact for precise atomized oil (oil mist) lubrication delivery. Main subsystems in the Carbon Shield console include: Electrical System Input power Alemite 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. Programmable Logic Controller (PLC) Housed in the secondary electrical cabinet are the PLC, (Fig.03) 24 VDC power supply, and digital as well as analog modules which provide the monitoring and control functions of the Carbon Shield system. The PLC also drives the HMI which provides a visual display of system status, parameter values and alarm conditions on the door of the main cabinet. Change in wiring may result in potentially hazardous conditions, death, severe injury or equipment damage. Wiring of the PLC and associated devices, power connections to the heaters, sensor connections and all cabinet penetrations must be done by qualified personnel in accordance with electric codes and regulations for electrical installation in hazardous classified locations. Fig. 03 PLC Box open Cabinet The NEMA 4X stainless steel cabinet has centerlocking weather-sealed doors with a three-point locking system. The door is sealed with foam in place gasket and all penetrations are sealed with gaskets or sealant as appropriate.

12 10 Alemite Carbon Shield Service Sheet Human Machine Interface (HMI) The touch screen on the front of the Carbon Shield cabinet is an HMI (Fig.04) which provides a color visual display of system status, parameter values and alarm conditions. The HMI is also the access port for set up and programming of the system parameters at start up. The HMI is connected to the PLC by a communication cable. The PLC sends: 4-20 ma control signals to the transducer/ regulator for air pressure/mist pressure control Digital outputs to DC interposing relays to control: Air heater Oil heater Local status red light on top of cabinet Local status green light on top of cabinet Remote status light or buzzer in control room Oil input refill solenoid Should the level sensor or any transducer/ transmitter indicate an abnormality, the PLC: Illuminates the red light on top of the cabinet Displays an alarm message on the HMI Fig. 04 PLC Password Information User names and passwords are factory set and provided at the time of delivery. They allow the appropriate access to the two password protected screens in the HMI. The administrator user name and password grants access to Set Up and Change Parameters screens. The supervisor 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

13 ALEMITE CARBON SHIELD SERVICE SHEET 11 Mist Head Assembly Within the mist head, (Fig. 05) oil is atomized by high-velocity air which creates tiny lubricant particles. Large particles are removed from the air stream and returned to the reservoir by a baffle which is screwed to the mist head. The remaining air-suspended mist particles travel through the distribution system at low pressure and velocity to an application fitting to deliver lubricant to a destination lubrication point. 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 pressure. Mist pressure is displayed on the user interface (HMI) on the cabinet door. (Fig.04) In addition, an analog pressure gauge allows the operator to view the actual oil mist pressure right at the tank assembly. (Fig. 08) Fig. 05 Oil Mist Outlet The oil is drawn into the mist head for atomization and then exits 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. Fig. 07 Fig. 08 Relief Valve The pressure relief valve begins to open at approximately 6 psi (0.42 kg/cm 2 ) and fully opens should mist pressure rise to 10 psi Fig. 06 Fig. 09

14 12 Alemite Carbon Shield Service Sheet Tank Assembly The tank assembly (Fig. 10) contains an oil reservoir which stores the oil for mist production, mist head assembly, oil heater, temperature and pressure sensors and a capacitive level sensor. 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) Fig. 13 Fig. 10 Loader Fitting A loader fitting allows oil to be added to the reservoir with a manual bucket pump when the optional automatic refill package is not purchased. (Fig 11) Air Pressure Control Customer-supplied instrument-quality air connects to the left side of the console s cabinet using a ½ inch 150-pound stainless steel screw flange. (Fig. 14) From the flange, the air flows through the filter/regulator which is equipped with a gauge, a 5 micron filter and a moisture separator with automatic drain. (Fig. 15) The pressure gauge allows the user to view the inlet pressure and to set the incoming air pressure between 70 psi and 95 psi (4.92 to 6.68 kg/cm 2 ) at start-up. Fig. 11 Fig. 12 Capacitive Level Sensor The console s oil reservoir contains a capacitive level sensor, which detects change in oil level as a function of change in capacitance between sensor and reservoir wall. The level sensor provides 4-20 ma signals to the PLC for level control and oil consumption monitoring. Sensor wiring is done at the factory. The level sensor is UL/CSA certified for service in Class I, Division 2 environments and measures the oil level in the reservoir with accuracy. It is calibrated to work with oil only. (Fig. 12) Fig. 14 Instrument air inlet 1/2 NPT Fig. 15

15 ALEMITE CARBON SHIELD SERVICE SHEET 13 Air Heater Package (optional) Once air passes through the 5 micron filter, it is desirable that the air be temperature controlled before reaching the mist head assembly. An optional air heater package can be installed to maintain air temperature at 100 degrees F (37.8 degrees C). Cycling of the air heater for control of temperature is achieved by the PLC with input from a thermocouple mounted in the air piping at the air heater outlet. (Fig. 15) Two sizes of air heaters are available. Consoles equipped with 1.0 SCFM, 2.3 SCFM and 4.3 SCFM mist heads require a 500 watt air heater. Mist head capacities of 9.7 SCFM, 13 SCFM and 21 SCFM require a 1000 watt air heater. Heater housings meet NEMA 4/7 specifications. Air heater packages are set to maintain air temperature at 100 degrees F (37.8 degrees C). (Fig. 13) and are available for either 120 VAC or 240 VAC to match the incoming line voltage. Transducer-Booster Assembly The Carbon Shield console uses electronic closed loop feedback between a pressure 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 psi ( kg/cm 2 ). 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 operators with a visual indication of the mist pressure. Also, air & mist pressure gauges are available in the cabinet. (Fig. 8 & Fig.14) Temperature gauge Air Heater Thermocouple Fig. 16 Oil Systems Fig. 15 Air System Damage to equipment can occur if ordinary plant/shop air is used. Use filtered and instrument-quality air only. Oil Inlet (Manual or Optional Automatic Refill) Manual oil refill is done through a loader fitting on the front of the mist head. (Fig. 10) For automatic refill the oil inlet line from the bulk storage system connects directly to a ¾ inch NPT inlet to the 10 micron filter assembly. Filtered oil enters the reservoir of the main generator when the 120/240 VAC solenoid valve is energized by the PLC in response to a low oil level signal from the level sensor (Fig. 11). The current usefull amount of oil in the main reservoir is displayed through the Parameter Valves screen in the HMI. In addition, sight glass provides operators a visual indication of the resulting oil level. (Fig. 16)

16 14 Alemite Carbon Shield Service Sheet Fig. 17 Bulk Oil Storage System (Accessory) The bulk oil storage system (Fig 17) operates in conjunction with the auto-refill option to continuously replenish oil in the reservoir. The bulk oil tank is designed to be installed close to a supply route for ease of maintenance and installation. The 110 gallon (416 L) tank is sloped to allow any water to drain away from the pump suction. A single air operated oil pump is used to transfer oil from bulk storage tank to the reservoir of the main and the back up generators. A pressure relief valve is provided to vent excess pressure resulting from thermal oil expansion created by daily ambient temperature variations. The installer/customer is responsible for connecting pipes between the bulk oil tank and the main console. Fig. 18 Oil Temperature The PLC monitors oil temperature by means of a thermocouple in the tank and maintains the temperature 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 and comes fully equipped with its own air pressure controls, mist generating head, oil reservoir, and instrumentation package. A separate ON/OFF switch located inside the rear cabinet and is used to power the control of the backup unit. The heater for the backup unit will be activated at all times, but controlled by a thermostat to provide the desired oil temperature. The back-up generator oil reservoir is filled manually or from the bulk storage tank if the optional auto refill feature is selected. Important Note: The backup generator is intended for intermittent use only. When operated for purposes other than to perform maintenance routine work on the main unit, it should be checked at the beginning of every shift. Fig. 19

17 ALEMITE CARBON SHIELD SERVICE SHEET 15 Cabinet Cooling (optional) An optional cabinet cooling feature is available for Carbon Shield systems that operate in high ambient temperature conditions. The cooling unit s integral vortex tube directs chilled air into the main cabinet to maintain the internal temperature within the operating limits of the various electronic controls. The cooling unit is non-electrical and thermostatically controlled. Clean, dry, compressed instrument air is the only power source for the cooler. It operates in two stages, 2,500 BTU and 5,000 BTU, depending on the temperature conditions. (Fig.19) 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 operating parameters fall within the expected range. The red lamp flashes on and off when any alarm conditions occur and during system setup. The PLC also sends the same indication signals for display on the HMI. Fig. 20 Cabinet Purge (Optional) An optional feature recommended for highly contaminated areas. The system works by supplying compressed air at proper flow and pressure to eliminate or reduce entry of contaminants to the enclosure. Fig. 22 Solenoid Valves The normally-closed solenoid valves are controlled by the PLC to allow oil to enter the reservoir and air to flow into the oil mist system. (Fig.22). Solenoid valves are available for either 120/240 VAC to match incoming line voltage. Oil solenoid Photo to come Air solenoid Fig. 23 Fig. 21

18 16 Alemite Carbon Shield Service Sheet INSTALLATION Site Preparation Install your Carbon Shield cabinet in an area with sufficient space (Fig. 22, 23) to accommodate: The opening of the cabinet door All system connections electric, air, oil and distribution piping A back-up console (recommended option) with a changeover valve Suggested minimum floor space (allowing for the equipment and maintenance access): 8 feet x 10 feet (or 2.4m 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. Fig. 25 Main unit 1. Prepare the surface with four anchor bolts (3/8 or 10mm) at the required locations (eight bolts if a backup unit is included) (Fig 24) 2. Lower the console over the bolts a. Fasten the console securely to the anchors with nuts and washers Fig. 26 Anchor bolts location for main and back up units Fig. 24 Main unit with back-up unit

19 ALEMITE CARBON SHIELD SERVICE SHEET 17 Systems Connections With the console secured, the air, oil, and electrical systems can be connected. This equipment is designed to work in Class I, Division 2, Groups B, C, and D, Temperature Code T4 Hazardous Locations. Always de-energize and ground this equipment. Read and understand this manual before installation, operating, or maintaining the equipment. Work on this equipment should be done by qualified personnel. The use of unauthorized parts or tampering by unqualified personnel may result in dangerous conditions which may cause death, severe injury, or equipment and property damage. Follow all safety instructions contained herein. To prevent contamination or clogging of the piping, fittings or both. Seal all air and oil connections with Loctite 592 (Teflon). Do not apply sealant to the first two (2) threads. Air System Connections Inlet Air The installation of a manual shut-off valve at the air inlet point outside the cabinet is recommended. The customer-supplied air line connects to a flow diverting ball valve on the left side of the mist console. This valve allows for the air supply to be re-directed to the main or backup unit. This is not a shut-off valve. (Fig. 25) Fig. 27 Note: Air delivered to this connection must be dry and filtered instrument-quality and the pressure regulated to psi ( kg/cm2). Oil Inlet (with optional auto-refill package) The customer supplied oil inlet line connects to the ¾ inch NPT at the inlet side of the oil filter assembly. (Fig. 25) There is a ¼ inch 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). Fig. 28

20 18 Alemite Carbon Shield Service Sheet Oil Inlet (with manual refill option) Manual refilling of the oil reservoir is done through the loader fitting mounted on the mist head (see Fig. 10). Refilling must be done through the loader fitting to prevent spillage inside the cabinet. Mist Outlet (without a backup unit) The customer-supplied distribution line connects to the console at the 2 inch 150 pound screw flange directly on the right side of the control cabinet. (Fig. 27) Fig. 29 Mist Outlet (with backup unit) When a backup unit is provided, the customer mist connection is at the 2 inch pipe T on the right side of the cabinet where the piping connects the main and backup units together. (Fig. 28) Electrical System Potentially hazardous conditions. May result in death, severe injury, or equipment damage. All wiring must be done in accordance with the appropriate regulations including NEC, UL, and applicable local codes specific to the area hazardous classification. Any modifications to the wiring systems can invalidate the hazardous rating This equipment is wired by UL certified panel shops. Special cable grips, cable types, hubs and sealing practices are employed to establish and maintain the integrity of the hazardous ratings. Power All electrical connections must be made by qualified personnel only. Prior to applying power to a new installation, ensure all terminal screws are secure. Customer provides 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) Fig. 31 Fig. 30

21 ALEMITE CARBON SHIELD SERVICE SHEET 19 Connections-DCS/ Control Room Alarm A dry set of contacts is provided for the end user to connect an alarm light or other fault indicating device in the control room. A small hub is provided for the cables to enter the cabinet on the left side. See wiring diagram for connection details. Wiring must be performed by qualified personnel in accordance with electrical code requirements for hazardous-classified locations as applicable. DP-9 female connector and terminals for power supply and functional ground are located beneath the front cover of the PROFIBUS module (fig 32). Fig. 34 Profibus Module Fig. 32 Connections to Communication Modules Connections to communication modules are different based on the type of communication modules specified by the customer. The Ethernet module requires 2 x 8 pin RJ 45 jacks. The jack is located beneath the front panel of the module (Fig 31). The Modbus module is supplied with an integrated RS 422/485 serial interface 15-pin connector located under the front cover of the Module. (Fig 33). Fig. 35 Modbus Module Fig. 33 Ethernet Module Wiring of communication modules must be done in accordance with hazardous location requirements by qualified personnel. Important Note: Alemite supplies a communication ready unit as an optional feature of the Carbon Shield system. The user is responsible for wiring, and interfacing to the native communication system. The above information is provided for reference only.

22 20 Alemite Carbon Shield Service Sheet operation Drain Connections A single drain connection is provided on the bottom of the main enclosure. The tank drain line discharges through a ball valve beneath the tank into a small sump. The 1½ inch pipe cap must be removed before the tank or any spilled oil is drained from the enclosure. (Fig. 34) 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) Important Note: The cabinet drain can be permanently plumbed to a waste oil system if desired, but a shut-off valve must be provided at the bottom of the cabinet to maintain cabinet sealing when the drain is not in use. Fig. 37 Shown in off position NEW PHOTO TO COME Ensure that the unit is properly grounded through the grounding lug supplied inside the cabinet. (Fig. 36) Fig. 36 Fig. 38 back off the inlet air pressure regulator (inside the cabinet) to its minimum setting before opening the air line to the oil mist unit. (Fig. 37)

23 ALEMITE CARBON SHIELD SERVICE SHEET 21 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. Fig. 39 For systems with the optional auto-refill package, open the ball valve in the incoming oil line (left side of the oil mist reservoir). (Fig. 38) Fig 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, or wait for the Alemite home screen to show. (Fig 42). Fig. 40 Turn on the air supply to the refill pump. (located at the bulk oil tank)

24 22 Alemite Carbon Shield Service Sheet Fig 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 Select Main Menu. Main Menu has 7 selections available. System Setup is located in the upper left corner (Fig 47). Fig Touch the User Name window. (Fig. 48) Important Note: User name and password are factory set and supplied at the time of system delivery. Fig. 48

25 ALEMITE CARBON SHIELD SERVICE SHEET 23 Fig. 49 9a. Type the user name on the pop-up keypad and then press the Enter key the backward facing arrow on the keypad s lower right corner. 9b. Touch the Password window. (Fig.50) Fig. 49 9d. Select Setup button again. (Fig.52) Fig. 50 9c. Type in 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.

26 24 Alemite Carbon Shield Service Sheet Fig Select Tank Size in upper left corner. Choose 3 gallon (11.4 L) tank (Fig 53). Fig a. If the unit is equipped with the automatic refill option, let the automatic refill system fill the tank to 3 gallon (11.4 L) level. (Fig. 54) 10b. Note oil level as displayed on HMI and compare this level to the site glass. Allow several minutes for the oil level to settle. 11. If the oil level is within 5% of the displayed level, the oil you are using is compatible with the factory default level calibration and your system requires no further calibration. 11a. Now you may elect to keep the 3 gallon (11.4 L) capacity setting or change to a 5 gallon (18.9 L) capacity setting. 11b. If 5 gallon (18.9 L) tank is selected, let the automatic refill complete the operation. 11c. Go to step 25 of this procedure. 12. If 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, always stop the refill or drain the tank up to about ¼ gallon of the intended mark and wait for the level in the sight glass to stop changing. This may take two to three minutes. 15. Select Calibrate Oil Level located in the upper center of the System Setup screen (Fig 53). 16. Follow instructions on the Calibrate Oil Level screen: (Fig 56) a. Set tank size to 5 gallons (18.9 L) with Auto Refill OFF. b. Press the OIL SOL button below to start oil fill. c. Press OIL SOL button a second time to stop oil fill. d. Fill tank until oil is even with zero on site glass. e. Press ZERO button. f. Fill tank to 5 Gallons on site glass. g. Press MAX FILL. Fig. 54

27 ALEMITE CARBON SHIELD SERVICE SHEET 25 18a. Choose the size nozzle you have. If you are unsure which nozzle you have, look for the nozzle size stamped into the 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. Fig When oil level is within 5% of the displayed level, return to System Setup and turn Automatic Refill on. Fig b. A small green indicator will appear in the upper right corner of the button when a selection is made (Fig 58). Fig Select Nozzle Size (Fig 57). Fig c. If an incorrect nozzle size is selected, simply select the proper nozzle size, the green indicator on the selected button will light up, and the selection process is complete. (Fig. 59) Fig. 57

28 26 Alemite Carbon Shield Service Sheet 19. Press Previous Screen to return to the Setup screen. (Fig. 60 & 61) Fig If the unit is equipped with an automatic refill system and/or an air heater package, select those options now on the right side of the System Setup screen. The HMI 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 unit should be illuminated. 24. If the red status light is illuminated, select the Alarms button at the bottom of the screen. Scroll through the alarm list. Refer to the manual in the alarms section to address each alarm displayed. 25. If the mist pressure matches the set point, the alarms are cancelled and the system is in Normal operation. The HMI will revert to the default screen and the System OK message will appear on the upper right corner of the screen (Fig. 66) Fig Notice the third button from the top in the left hand column (fig 61). If this button displays Please Wait, the system is waiting for the Oil Temperature and level to stabilize. Check to see if the oil mist output is near 20 H2O. When all conditions are met for this step the Please Wait will change to Set Up Done (Fig 66). When this happens, the Carbon Shield unit has gathered all the information required for the system parameters to be monitored. Important: The end user should verify the correct operation of the entire oil mist installation down the stream from the Carbon Shield unit before completing the set up step below. In the next step, the end user will confirm that the current parameter values are to be monitored by the Carbon Shield unit. 21. Press the Setup Done button. Fig If the pressure does not match the normal set point, of 20 water column the PLC will detect a possible leakage or possible blockage condition and will display an alarm accordingly. (See section Using Adaptive Mode on how to adjust system parameters and clear the alarm) 27. Return to the main menu and re-enter the password if required as depicted below. (Fig. 68) 27. When finish, exit to the main menu.

29 ALEMITE CARBON SHIELD SERVICE SHEET 27 Using Change Parameters Feature 1. The Change Parameters feature allows an end user with the required password to change the system setup parameters. For example the user can change the CFM output by changing the mist pressure, or change the oil or air temperature set point. (Fig. 68) Fig. 70 Fig. 68 at 20 inches of water column, or adjust the mist pressure to produce the mist flow rate that is closest to the ideal flow rate for the points needing lubrication. (Fig. 70) 4. The user can also select the Oil Temperature button to adjust the oil temperature as needed. Adjusting oil temperature also adjusts air temperature to the same value. (Fig.71) 2. The Carbon Shield controller allows the end user to adapt the system to the installation variables such as piping distance, and diameter, number of fittings and piping bends, etc. By selecting the Change Parameters button, the user can access the screen below. (Fig. 69) Fig. 71 NEW IMAGE TO COME Fig 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 Fig. 71

30 28 Alemite Carbon Shield Service Sheet Using Adaptive Mode Feature The Adaptive Mode feature allows the end user to accept system operating settings different from the default values stored in the PLC. These differences can be produced by the actual installation conditions such as pressure drops due to the number of nozzles or length of the distribution pipes. The Adaptive 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) Fig Select the Adaptive Mode button to accept the current system parameters (Fig. 74) Fig. 75 Fig Enter the user name and password. (Fig. 73) 6. The screen will show the Adaptive Mode (Fig. 75) message and after a short time delay the System OK will appear. (Fig. 76) Fig Select the Set Up button again. (Fig. 72) Fig. 76

31 ALEMITE CARBON SHIELD SERVICE SHEET 29 Monitoring Functions The Carbon Shield unit is equipped with sensors which monitor the different operating parameters of the system. The signal from the various sensors is fed into the conditioning circuit of the controller. The conditioning signal is interpreted and scaled by the PLC to produce the parameters displayed. To access the operating status of each parameter press the Parameter Values button on 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 HMI. (Fig. 78) Fig. 77 Fig. 78 Important Note: If the reported alarm (Fig. 79) is due to intentional change such as adding or removing lubrication points to the system, the user can accept the change as new setting through the adaptive mode function. (See Adaptive Mode Section D) Fig. 79

32 30 Alemite Carbon Shield Service Sheet Alarm List Air and Mist related alarms 1. Blockage Issued when a mist pressure increase from the set point value, equivalent to approximately 0.5 CFM, is detected by the pressure sensor. There is a time delay of 5 seconds before the alarm is issued. 2. Leakage Issued when a mist pressure drop from the set point value, equivalent to approximately 0.5 CFM, is detected by the pressure sensor. There is a time delay of 5 seconds before the alarm is issued. 3. Low mist pressure Issued when the pressure sensor detects a mist pressure below Set Point. There is a time delay of 5 seconds before the alarm is issued. 4. High mist pressure Issued when the pressure sensor detects a mist pressure above Set Point. There is a time delay of 5 seconds before the alarm is issued. 5. Mist Pressure Sensor Fault Issued when the PLC detects the mist pressure input to be out of 4-20mA range. There is no time delay. 6. Vacuum Sensor Fault Issued when the PLC detects the vacuum sensor input to be out of 4-20mA range. There is no time delay. 7. High air temperature Issued when the air thermocouple detects an air temperature above 170 F (76.7 degrees C). There is no time delay. 8. Low air temperature Issued when the air thermocouple detects an air temperature below 85 F (29.4 degrees C). There is no time delay. 9. Air Temp Sensor Fault Issued when the PLC 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 the distribution line. There is a time delay of 5 seconds before the alarm is issued. 11. Wrong CFM Lo Issued when the mist pressure is at 20 H2O (or other chosen set point) but the mist flow is less 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 bigger than the one actually installed. Another possible cause is a large leakage in the distribution line. There is a time delay of 5 seconds before the alarm is issued. 12. Mist pressure set point change Only issued when the mist pressure is changed using the Change Parameters screen in the HMI. This alarm is meant to inform you that you are changing a key parameter in the system from the original/last set up values. This alarm also warns the user that a change in oil consumption will follow. No time delay. 13. Check Air Supply or Transducer Fault Issued when the transducer regulator is out of range of 4-20mA. Large leakage or blockage and/or the loss of enough air supply pressure are generally the causes for this alarm. Troubleshooting this problem is outside the scope of this manual. Please contact your Alemite representative. There is no time delay for this alarm.

33 ALEMITE CARBON SHIELD SERVICE SHEET 31 Oil Related Alarms 1. Check Oil Screw Issued when the PLC detects a 2% change in the input from the vacuum sensor but no change in mist pressure, oil level or oil temperature has been detected. This alarm warns the user that a change in the oil vacuum and potentially the oil consumption has occurred. Determining the magnitude of this change is outside of the scope of the Carbon Shield control system design. The end user should investigate the situation and take corrective action. If the change is determined to be acceptable, the end user can clear this alarm using the Adaptive Mode function. This alarm can also be triggered when draining the reservoir while the unit is running. There is a time delay of 5 seconds before the alarm is issued. 2. oil Temp Alarm Hi Issued when the oil thermocouple detects an oil temperature above 170 F (76.7 degrees C). There is no 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 Lo Issued when oil in the tank is at about 0.25 gallons (0.95 L) of useful oil. There is no time delay. 7. Oil LVL Alarm Hi Issued when tank is overfilled by 0.25 inches (0.6 cm) above max. level. It may indicate leaking oil solenoid or level sensor needs calibration. See Start Up procedure in this manual for level sensor calibration. 8. Oil Refill Alarm, Check Oil Level/Refill Valve Issued when the PLC starts the oil refill system and the oil level in the tank doesn t increase after 5 minutes. Other Alarms 9. Setup is not Finished Select Setup Done Issued during the set up sequence to warn the user that the Carbon Shield unit still requires their input. This condition indicates that the system is not ready to operate autonomously.

34 32 Alemite Carbon Shield Service Guide Remote Communications and Alarms The Carbon Shield console is capable of communicating information and alarms to remote locations in two different modes: 1. Dry Set of contacts 2. Interface to native DCS systems via: a. Modbus RTV b. Modbus TCP/IP c. Ethernet Hard Wired Relay General Alarm Signal A dry set of contacts at relay R04 is provided for the end user to connect their alarm light or buzzer in the control room. The normally closed set of contacts provides the same alarm (red LED light) signal as the red light on top of the Carbon Shield Unit. The normally open set of contacts is made closed only when the system is ok and the green LED on top of the unit is lit. See wiring diagram for details. Change in wiring will may result in potentially hazardous conditions, death, severe injury and equipment damage. Wiring of the PLC and associated devices, power connections to the heaters, sensor connections and all cabinet penetrations must be done by qualified personnel in accordance with all applicable electric codes and regulations for electrical installation in hazardous classified locations. Interface to Native DCS Networks As an option, Alemite supplies a communication ready Carbon Shield unit equipped with PLC with an integrated communication module. The most common method is Modbus (RS 422/485) RTU. Ethernet or Modbus TCP/IP communication is also available upon request. 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 In addition, Industrial Ethernet communications are available when required. The Carbon Shield units configured with Modbus RTU use a read-only datablock to store the data from the sensors. Standard Modbus commands can be used to poll the unit. This block is available using Modbus standard request Function Code 03. The master PLC should use address zero and request 38 bytes of data from the slave PLC (i.e. the Carbon Shield unit PLC).

35 Alemite Carbon Shield Service Guide 33 Important Note: The customer is responsible for connection to the communication module, interfacing and integration of the Carbon Shield PLC into the customer s native DCS system. (Fig. 85) PLC ETHERNET MODULE PLANT DCS SYSTEM MPI/PPI ETHERNET Fig. 85 PLC Program Loading This operation is done at the factory. Should a revision to the software or other actions require the PLC program to be reloaded, follow steps below. (Fig. 86) 1. Power down the 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. Follow start up sequence. (Page 20) Fig. 86 Potentially hazardous conditions. May result in death, severe injury, or equipment damage. Units must be shut-off before performing any maintenance.

36 34 Alemite Carbon Shield Service Guide Switching from Main to Backup Generator Follow the process described below to dampen the transient pressure resulting when the main generator is shut down 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 mist outlet valve Fig. 87

37 Alemite Carbon Shield Service Guide 35 maintenance checklist To help keep your Carbon Shield system operating at peak efficiency, create a periodic maintenance schedule covering all major components. Keep logs that detail the date and extent of your maintenance tasks. Units equipped with a communications module can capture data for logs electronically. Weekly o Inspect for air and oil-mist leakage o Clean inside of generator console and correct any leaks. o Conduct manual test of mist head s pressure relief valve o Check regulated air pressure and the supply air pressure Every Month o Check oil collection bottles/containers. Dispose of oil as needed Every Year o Replace oil inlet filter o Inspect hardware; make sure all connection are tight o 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/regulator element should be changed whenever the oil reservoir is cleaned. Manually Filling Oil Reservoir Should you need to fill the reservoir on your Carbon Shield system manually, follow these steps 1. Avoid overfilling: DO NOT fill the oil reservoir past the full mark. Without proper air space within the reservoir, the system will not function properly. Loader With the loader fitting on the mist head, you can add oil to the reservoir with a manual bucket pump. CLEAN THE LOADER FITTING BEFORE FILLING. NEW MAINTENANCE CHECKLIST TO COME

38 36 Alemite Carbon Shield Service Guide troubleshooting chart The following information provides general guidelines to identifying potential problems and possible solutions on the Carbon Shield system. For complete parts list, electrical schematics and component locations refer to the information contained in this manual. The Carbon Shield control system continously monitors all parameters involved in oil mist generation. As a result, it is very likely for the HMI to display more than one fault for the same problem. 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 may be beyond the possible solutions listed in this manual. Please contact Alemite customer service for assistance, or Siemens for PLC and HMI product support. If you cannot resolve your issue through our Trouble Shooting Section, please contact Alemite Customer Service department at

39 Alemite Carbon Shield Service Guide 37

40 38 Alemite Carbon Shield Service Guide Troubleshooting Chart Problem Possible Cause Possible Solution Not enough mist being produced 1. Reduced oil supply resulting in lean oil to air mixture. 1.1 Pull the relief valve ring. Visually inspect mist quality. Good mist should resemble smoke with no oil condensation visible. 1.2 Check oil level in the reservoir; 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. 2. Oil or Air Heater Malfunction. 1.4 Check oil suction screen for obstruction. 2.1 Confirm oil and air temperature. Factory default is 100 F (37.8 C). 2.2 Check fuses F1, F2, F9 and F10, and relays R0 and R1 for proper operation, replace if needed. 3. Excessive distribution line leakage or blockage. 3.1 Check for leakage or blockage.

41 Troubleshooting Chart 39 Troubleshooting Chart Problem Possible Cause Possible Solution Low mist pressure 1. Air supply pressure below 70 psi, or 4.92 kg/cm 2 (below 90 psi, or 6.33 kg/ cm 2, for 13 CFM & 21 CFM units) 1.1 verify the air supply pressure is between 70 and 150 psi (4.92 and kg/cm 2 ). Change over to the backup unit and adjust pressure as needed. 2. Regulator inside cabinet set to less than 65 psi, or 4.57 kg/cm 2 (Less than 90 psi, or 6.33 kg/cm 2, for 13 & 21 CFM units) 2.1 Adjust regulator pressure above 65 psi (4.57 kg/cm 2 ). Recommended setting is 80 psi, or 5.63 kg/cm 2 (95 psi, or 6.68 kg/cm 2, for 13 CFM & 21 CFM units) 3. Mist pressure set point set too low. 4. Change in installation conditions 3.1 Press the Parameter Values button on the main menu screen to display the mist pressure value. Factory default is 20 inches H 2 O 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 mist pressure level. 4.1 Low mist pressure may be the result of leakage in the mist supply lines. Check the alarm log for leakage alarm and time, repair as needed. 4.2 verify that mist fittings were not replaced by larger size or by a mist supply line. 5. Transducer failure 5.1 Transducer regulator out of range. Alarm log may indicate device malfunction which may require replacement.

42 40 Alemite Carbon Shield Service Guide Troubleshooting Chart Problem Possible Cause Possible Solution High mist pressure 1. Mist pressure set point too high. 1.1 Press the parameter values button on the main menu screen to display the mist pressure value. Factory default is 20 inches H 2 O column or 50mBar. 2. Mist fitting blockage or other distribution system related issue. 1.2 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 adjust to the desired mist pressure level. 2.1 High mist pressure 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. Transducer Regulator out of range alarm in the alarm log when there is no high or low mist pressure indicted in the HMI 1. Transducer Regulator malfunction. 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. 3.1 Transducer Regulator malfunction is very unlikely. The replacement of the transducer regulator is out of the scope of this manual. Please change over from the main unit to the backup unit. Turn off the power to the main unit and contact Customer Service at

43 Troubleshooting Chart 41 Troubleshooting Chart Problem Possible Cause Possible Solution Low air temperature 1. Air Heater malfunction 1.1 Press the Parameter Values button on the main menu screen to display the air temperature. Factory default is 100 F (37.8 C). 1.2 Ensure that the air supply pressure is between 70 psi and 150 psi (4.92 and kg/cm 2 ), and the regulated air pressure is between 32 psi and 40 psi (2.25 and 2.81 kg/cm 2 ). 1.3 Ensure that the mist pressure is above 10 in. H 2 O.* *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. Replace as needed. (Refer to Wiring Diagram) 1.6 Repairs to the Air Heater beyond this point are out of the scope of this manual. Please change over from the main unit to the backup unit. Turn off the power to the main unit and contact Customer Service at

44 42 Alemite Carbon Shield Service Guide Troubleshooting Chart Problem Possible Cause Possible Solution High air temperature 1. Air Heater and/or Control System malfunction. 1.1 Repairs to the Air Heater and/or Control System are out of the scope of this manual. Please change over from the main unit to the backup unit. Turn off the power to the main unit and contact Customer Service at Transfer rate from bulk oil tank to reservoir takes more than one hour. 1. Automatic Refill Valve inside the cabinet may be half open. 2. Oil Refill Solenoid malfunction. 3. Empty or malfunctioning Bulk Oil System. 1.1 Ensure that the oil supply valve to the reservoir is fully open. 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 psi ( kg/cm 2 ). 2.3 Check the operation of the oil 3.1 Check for clogged air filter element. 3.2 Check pump for obstructions. 4. Low supply air pressure 4.1 Check air supply pressure to the refill pump and correct as needed to give psi ( kg/cm 2 ).

45 Troubleshooting Chart 43 Troubleshooting Chart Problem Possible Cause Possible Solution Any Sensor out of range alarm in the HMI. Insufficient amount of oil mist or no mist produced (Potential problem may be unrelated to the Carbon Shield Unit internal workings) 1. Sensor failure is very unlikely. The Carbon Shield control system continously monitors all parameters involved in oil mist generations. As a result, the HMI could display more than one fault for the same problem. 1. Distribution line obstruction 2. Console Reservoir overfilled 3. Foreign material in application fitting(s) 4. Improper oil or incompatible oils 1. The replacement of Sensors is out of the scope of this manual. Please change over from the main unit to the backup unit. Turn off the power to the main unit and contact Customer Service at Remove low spots in distribution line. 2. Consult with Alemite Technical Service. 3. Clean distribution vent line(s). 4. Clean or replace application fitting(s). 5. Check with supplier on oils specific for oil mist lubrication.

46 44 Alemite Carbon Shield Service Guide reference Specifications Potentially Hazardous Conditions May result in death, severe injury, or equipment damage. All electrical components are rated for Class I, Division 2 hazardous locations. Substitutions will void the hazardous locations rating of the Carbon Shield System. Mechanical Systems Console Height* 58.9 in. (149.6 cm) Width* 35.5 in (90.2 cm) Depth* 37.6 in (95.5 cm) Material Stainless Steel Enclosure Rating NEMA 4X Cabinet Cooling Optional, vortex system Cabinet Purge Optional Environment Class I, Division 2, Groups B, C, and D, T4 Generator Nozzle CFM 1, 2.3, 4.3, 9.7, 13, 21 Back-up Optional Reservoir Capacity 3 and 5 Material Stainless Steel Oil heater Power 500 Watt Nominal Temp. 100 F (37.8 C) Temp. Range F ( C) Air heater Power 500 or 1000 Watt Nominal Temp. 100 F (37.8 C) Temp. Range F (-17.8 to 82.2 C) Air Supply Pressure Range Quality psi ( kg/cm 2 ) Instrument air, Dry Regulated air pressure to generator Nominal 80 psi (5.63 kg/cm 2 ) Min/Max 65/95 psi** ( kg/cm 2 )** Mist Pressure Head Nominal Range 20 Inches H2O Inches H2O (depending on the nozzle size) Bulk Oil Tank (Accessory) Capacity 110 Gallons (416 L) * Typical (with back up generator and 5 gallon, or 18.9 L, reservoir) **13 & 21 CFM Nozzles require psi ( kg/cm 2 )

47 Alemite Carbon Shield Service Guide 45 Specifications Electrical Systems Voltage Current Controller Annunciator (HMI) Control Analog Inputs 120 VAC or 240 VAC VAC, VAC Modular PLC platform Touch screen color panel Close loop PID control; temperature, pressure, and flow. Adaptive control mode (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 Security Mist Density Comm. Options Display Languages Measurement Units Temperature, pressure, and mist density trending Two level password access Quantifiable oil to air ratio Ethernet and Modbus English English and Metric

48 46 Alemite Carbon Shield Service Guide Parts List COMMON PARTS ALEMITE P/N Commissioning Service Parts List Two Years Service Parts List Gasket, Mist Oulet Y Y 4 parts in package Mist Head Assembly Kit -1 SCFM Y Job specific Mist Head Assembly Kit SCFM Y Job specific Mist Head Assembly Kit SCFM Y Job specific Mist Head Assembly Kit SCFM Y Job specific Mist Head Assembly Kit - 13 SCFM Y Job specific Mist Head Assembly Kit - 21 SCFM Y Job specific Nozzle Assembly Kit - 1 SCFM Y Y Job specific Nozzle Assembly Ki T- 2.3 SCFM Y Y Job specific Nozzle Assembly Kit SCFM Y Y Job specific Nozzle Assembly Kit SCFM Y Y Job specific Nozzle Assembly Kit - 13 SCFM Y Y Job specific Nozzle Assembly Kit - 21 SCFM Y Y Job specific SST Mist Fitting " H2O, 1/4" Tube Job specific SST Mist Fitting " H2O, 1/4" Tube Job specific SST Mist Fitting " H2O, 1/4" Tube Job specific SST Mist Fitting " H2O, 1/4" Tube SST Mist Fitting " H2O, 1/4" Tube Job specific SST Mist Fitting " H2O, 1/4" Tube Job specific O-Ring, Mist Head Y Y 4 parts in package O-Ring, Oil Screw X Y Y 4 parts in package Oil Sight Tube and Oil Temperature Gauge Y Mist Pressure Gauge Y Y Gasket, Tank Door Y Y 2 parts in package Pressure Relief Valve Y Y Gasket, Heater Removal Door Y Y 4 parts in package Gasket, Air Inlet Flange Y Y 4 parts in package Filter/Regulator Y Boaster And Air Pressure Gauge U Y Oil Filter (Auto Refill And Bulk Oil Tank) Y Oil Filter Media Y Y Air Filter Element Y Y Oil Thermometer Y Y Oil Pressure Gauge Y Y Valve, 2" NPT Full Port Ball Y Valve, 1/2' NPTt 3-Way Full Port Ball Y Valve, 1/4" NPT Full Port Ball Y Valve, 3/4" NPT Full Port Ball Y Notes

49 Alemite Carbon Shield Service Guide 47 Parts List COMMON PARTS ELECTRONICS ALEMITE P/N Commissioning Service Parts List Two Years Service Parts List I/P TRANSDUCER REGULATOR Y RELAY Y SOCKET, RELAY Y Air solenoid valve and Oil solenoid valve Y SENSOR, VACUUM Y SENSOR, PRESSURE Y Level sensor Y Alarm light globe green Y Alarm light globe red Y VALVE CHECK A Y Air heater, 120 VAC and 1000 W Y Job specific Air heater, 120 VAC and 500W Y Job specific Air heater, 240 VAC and 1000 W Y Job specific Air heater, 240 VAC and 500 W Y Job specific Oil heater, 120 VAC and 500 W Y Job specific Oil heater, 240 VAC and 500 W Y Job specific PLC memory cartridge w/ SW Y POWER SUPPLY, PLC Y THERMOCOUPLE MODULE Y THERMOCOUPLE Y PLC Y HMI Y CABLE, HMI COMMUNICATION Y Fuse kit U Y Y HMI memory cartridge with software Y OPTIONS Ethernet module Y Job specific Profibus module Y Job specific Modbus module Y Job specific Cabinet vortex cooling apparatus Y Job specific Enclosure Purge Package Y Job specific Notes

50 48 Alemite Carbon Shield Service Guide Parts List COMMON PARTS ACCESSORIES ALEMITE P/N Commissioning Service Parts List Two Years Service Parts List Manual Refill Pump Y Job specific Mist Collector Container Y Job specific Bulk Oil Storage Tank Job specific Manifold Assy., Mist Y Y Sightglass, Vent Y Y Sun Screen Prue Mist Kit Purge Mist Kit Drain Leg Kit Tube, 3/8 OD (10 ft) Tube, 1/4 OD (10 ft) BULK OIL TANK - PARTS Y Y Y Notes Job specific

51 Alemite Carbon Shield Service Guide 49 Wiring Diagrams PLC Analog Input/Output module wiring. (Fig. 90) Fig. 90

52 50 Alemite Carbon Shield Service Guide Wiring Diagrams Thermocouple Module Wiring. (Fig. 91) Fig. 91

53 Alemite Carbon Shield Service Guide 51 Wiring Diagrams Relay Wiring. (Fig. 92) Fig. 92

54 52 Alemite Carbon Shield Service Guide Wiring Diagrams Schematic diagram. (Fig. 93) Fig. 93

55 Alemite Carbon Shield Service Guide 53 References Carbon Shield Nomenclature Part No. Example: A B A 5 - B A 1 - U B A B A 5 General Configuration Area Reservoir Capacity Nozzle CFM 5 7 Hazardous 2 3 Gallon Stainless Steel 1 1 CFM 4 5 Gallon Stainless Steel CFM CFM CFM Electrical Configuration Control Voltage Air Heaters Control Communication Module A 120 VAC A 500 W A Local PLC & HMI 4 None** B 230 VAC B 1000 W C Other 5 Modbus C NONE 5 13 CFM 6 21 CFM **Dry set of contacts are standard B A 1 U B 2 Structural Configuration Mounting Cabinet Options Backup Generator B SS - NEMA 4X A Cabinet Cooling 1 Yes D Purge 2 No E None Accessories Certification Refill Option Others U UL A Manual 1 None B Auto 2 HMI Protective Cover C Auto w/bst* *Wired for Alemite Bulk Storage Tank (BST) with Level Switch. BST sold separately. Hazardous location, 5 gallon SS reservoir, 9.7 CFM nozzle, 120 VAC control voltage, 1000 W air heater, PLC and HMI, Modbus communication, SS NEMA 4X enclosure, cabinet cooling option, Back-up unit, UL Listed for Class I Division 2 Groups BC & D T4, auto refill and HMI Protective Cover.