Letter of Transmittal

Transcription

1 AERZEN USA CORPORATION 108 Independence Way * Coatesville, PA Main Phone: * Fax: Letter of Transmittal Company: Birch Bay Water & Sewer District 7096 Point Whitehorn Rd Blaine, WA Attn: Mike Sowers Subject: Sewer - CIP WWTP Aeration Basin Upgrades Transmittal #: Date: April 11, 2016 PO #: Job #: SO WE ARE SENDNG YOU Letter Purchase Order Submittal O&M Manual Other Revised, with responses to review comments DOCUMENT TYPE: pdf # OF COPIES: (1) via TRANSMITTED as checked below: For Approval For Your Use As Requested As Built Action Specified Below Remarks: Copy To: Kristin Faulkner Treatment Equipment Company Paul Schuette Aerzen USA Corporation PROJECT MANAGER: NAME Margie Jarrow Tel: Fax: mjarrow@aerzenusa.com Signed: Margie Jarrow

2 Submittal (revised ) SECTION ROTARY LOBE HYBRID BLOWER Birch Bay Water & Sewer District Manufacturer/Service/Parts Local Representative Purchaser Aerzen USA Corp. Treatment Equip. Co. Birch Bay Water & Sewer Dist 108 Independence Way Bel Red Rd # 101C 7096 Point Whitehorn Rd Coatesville, PA Bellevue, WA Blaine, WA (tel) (tel) (tel) (fax) (fax)

3 Water, Industrial and Domestic Wastewater, Reclaimed Water, Biosolids, Odors and Air Emissions: Treatment Design, Planning, Funding, Studies, Modeling, Operation, Permitting, Management ESVELT ENVIRONMENTAL ENGINEERING, LLC Phone: EAST DALTON AVENUE, SPOKANE WA 99212, Date: March 13, 2016 Project: Birch Bay Water and Sewer District (District) Wastewater Treatment Plant (WWTP) Technical Memorandum: TM-EEE-5 Rotary Lobe Hybrid Blower Submittal Review Prepared For: Prepared By: Mr. Rodney Langer, P.E. Principal CHS Engineers Bel-Red Road, Suite 101 Bellevue, WA Allison Esvelt, MSCE, PE, BCEE Principal Esvelt Environmental Engineering, LLC Recommended Action: Revise and Resubmit addressing the items below. 1. General: The text in Section 2 - Sales Description and Section 5 - Motor Submittal does not appear to have been printed properly. Please correct and resubmit these sections. Specification Section Paragraph 1.04.D.4: Submit detailed information for bearings, v-belts, sheaves, and gauges. 3. Paragraph 1.04.D.5: Include performance curves showing capacity in SCFM and ICFM, differential pressure, db(a) noise pressure level, rotor speed, and blower horsepower from 0 percent to 130 percent of design capacity at design inlet conditions (pressure, temperature, and relative humidity). 4. Paragraph 1.04.D.7: Submit v-belt drive service factor calculations. 5. Paragraph 1.04.D.8.k: Submit motor manufacturer s certified bearing life. 6. Paragraph 1.04.D.13: Submit warranty as specified in Paragraph 1.06 for both blower assembly and motor. 7. Paragraph 1.04.E and F - Transmittal Procedures: Please provide copies of the Operation and Maintenance Manuals to the Buyer as specified and in accordance with the requirements of this paragraph. 8. Paragraph 1.06.A - Warranty: Aerzen s standard warranty is rejected. The Seller must provide the specified warranty per the Contract which begins on the Date of Seller s Certificate of Installation and Field Testing. 9. Paragraph 1.06.C: Furnish motor manufacturer s 2-year warranty. Esvelt Environmental Engineering LLC 1 Birch Bay Water and Sewer District WWTP January 2016 Fine Bubble Diffuser Submittal TM-EEE-4

4 10. Paragraph 2.01.C.1: Maximum blower speed of 7,122 RPM is approved. 11. Paragraph 2.03.K: Insulation surrounding the discharge silencer may be eliminated. 12. Paragraph 2.07.H: Motor speed of 3,600 RPM is approved. 13. Paragraph 2.07.V: Motor must be inverter-duty rated per NEMA MG1 as specified. Verify requirement. 14. Paragraph 2.07.W: Verify specified motor bearing life of 100,000 hours. 15. Paragraph 2.09: Aerzen s standard non-stainless steel pressure relief valve is approved. 16. Paragraph A and B: Inlet and discharge gauges are still required per the specifications. Submit product information. 17. Paragraph C: Inlet and discharge pressure transducers may be supplied in lieu of pressure switches. 18. Paragraph 2.012: Discharge temperature transducer may be supplied in lieu of temperature switch. However, the temperature gauge is still required as specified. Submit product information. 19. Paragraph B.9: Noise level of not greater than 77 db(a) at 3-feet from enclosure is approved. 20. Paragraph 2.017: Furnish and provide submittal on specified nameplate. 21. Paragraph 2.018: Furnish stainless steel fasteners as specified. 22. Paragraph A.4: Submit letter stating that the Owner will receive a credit for the specified spare bearings, seals, and gaskets should maintenance be required and Owner require shipment of these parts to a qualified service center or to the factory. 23. Paragraph B and C: Package and provide storage container for spare parts as specified. 24. Paragraph 3.01.B.2 - IEEE 112 Tests: Perform tests in accordance with IEEE 112 as specified. Submit IEEE 112 Form A-1 as specified prior to shipment. 25. Paragraph 3.01.C: Furnish calibration certificates for instrumentation as specified prior to shipment. Esvelt Environmental Engineering LLC 2 Birch Bay Water and Sewer District WWTP March 2016 Rotary Lobe Hybrid Blower Submittal TM-EEE-5

5 Date: April 11, 2016 Project: Birch Bay Water and Sewer District (District) Wastewater Treatment Plant (WWTP) Rotary Lobe Hybrid Blower Submittal Review Aerzen Responses to Revise and Resubmit Comments. 1. General: The text in Section 2 - Sales Description and Section 5 - Motor Submittal does not appear to have been printed properly. Please correct and resubmit these sections. Corrected. Specification Section Paragraph 1.04.D.4: Submit detailed information for bearings, v-belts, sheaves, and gauges. Information for the belts and pulleys has been added to Submittal Section Paragraph 1.04.D.5: Include performance curves showing capacity in SCFM and ICFM, differential pressure, db(a) noise pressure level, rotor speed, and blower horsepower from 0 percent to 130 percent of design capacity at design inlet conditions (pressure, temperature, and relative humidity). Applicable curves have been added to Section Paragraph 1.04.D.7: Submit v-belt drive service factor calculations. Added to Submittal Section Paragraph 1.04.D.8.k: Submit motor manufacturer s certified bearing life. Added to Submittal Section Paragraph 1.04.D.13: Submit warranty as specified in Paragraph 1.06 for both blower assembly and motor. The Warranty, and the Terms and Conditions are addressed with the commercial review by the Aerzen Contract istrator. 7. Paragraph 1.04.E and F - Transmittal Procedures: Please provide copies of the Operation and Maintenance Manuals to the Buyer as specified and in accordance with the requirements of this paragraph. The O&M manual will be provided upon receipt of a fully approved Submittal. 8. Paragraph 1.06.A - Warranty: Aerzen s standard warranty is rejected. The Seller must provide the specified warranty per the Contract which begins on the Date of Seller s Certificate of Installation and Field Testing. The Warranty, and the Terms and Conditions are addressed with the commercial review by the Aerzen Contract istrator. 9. Paragraph 1.06.C: Furnish motor manufacturer s 2-year warranty. A 3 year warranty on the motor is extended by the motor manufacturer. See Submittal Section 5.

6 10. Paragraph 2.01.C.1: Maximum blower speed of 7,122 RPM is approved. Noted. 11. Paragraph 2.03.K: Insulation surrounding the discharge silencer may be eliminated. Noted. 12. Paragraph 2.07.H: Motor speed of 3,600 RPM is approved. Noted. 13. Paragraph 2.07.V: Motor must be inverter-duty rated per NEMA MG1 as specified. Verify requirement. The motor is inverter-duty rated. See nameplate data in Submittal Section Paragraph 2.07.W: Verify specified motor bearing life of 100,000 hours. Added to Submittal Section Paragraph 2.09: Aerzen s standard non-stainless steel pressure relief valve is approved. Noted. 16. Paragraph A and B: Inlet and discharge gauges are still required per the specifications. Submit product information. Supplying inlet and discharge gauges is redundant and not necessary. The specification references PD blower instrumentation in nature and does not meet Aerzen s requirements for a Hybrid rotary lobe compressor. Aerzen will supply the AERtronic which will monitor the inlet and discharge pressures and temperatures, as well as control the enclosure cooling fan. The AERtronic will monitor the motor temperature with a temperature switch. The AERtronic will provide a digital display of temperature and pressure readings. It will provide hardwire alarm and/or fault signals if operated outside of the normal operating parameters. In addition the AERtronic will notify/alarm the operator of maintenance requirements such as oil changes, belt inspection/replacement and filter service. 17. Paragraph C: Inlet and discharge pressure transducers may be supplied in lieu of pressure switches. Noted. 18. Paragraph 2.012: Discharge temperature transducer may be supplied in lieu of temperature switch. However, the temperature gauge is still required as specified. Submit product information. Supplying a discharge temperature gauge is redundant and not necessary. The specification references PD blower instrumentation in nature and does not meet Aerzen s requirements for a Hybrid rotary lobe compressor. Aerzen will supply the AERtronic which will monitor the inlet and discharge pressures and temperatures, as well as control the enclosure cooling fan. The AERtronic will monitor the motor temperature with a temperature switch. The AERtronic will provide a digital display of temperature and pressure readings. It will provide hardwire alarm and/or fault signals if operated outside of the normal operating parameters. In addition the AERtronic will notify/alarm the operator of maintenance requirements such as oil changes, belt inspection/replacement and filter service. 19. Paragraph B.9: Noise level of not greater than 77 db(a) at 3-feet from enclosure is approved. Noted. 20. Paragraph 2.017: Furnish and provide submittal on specified nameplate. Material is Anodized Aluminum Black, Fade Resistant coating. See nameplate photo in submittal section Paragraph 2.018: Furnish stainless steel fasteners as specified. Stainless steel fasteners will be provided.

7 22. Paragraph A.4: Submit letter stating that the Owner will receive a credit for the specified spare bearings, seals, and gaskets should maintenance be required and Owner require shipment of these parts to a qualified service center or to the factory. Exception was taken in the bid package to supplying spare bearings, seals, and gaskets; and not included in the price quoted. A letter stating that the Owner will receive a credit will not be provided. Additionally, Aerzen does not have a system for issuing and tracking credits for spare parts. These parts are normally stocked items housed at the Aerzen USA Coatesville, PA warehouse and can be shipped within 24 hours notice upon request of customer order. 23. Paragraph B and C: Package and provide storage container for spare parts as specified. A storage container for spare parts will be provided. 24. Paragraph 3.01.B.2 - IEEE 112 Tests: Perform tests in accordance with IEEE 112 as specified. Submit IEEE 112 Form A-1 as specified prior to shipment. The motor will be tested in accordance with IEEE 112 as specified. See BALDOR MOTOR ROUTINE TEST PROCEDURE in Section Paragraph 3.01.C: Furnish calibration certificates for instrumentation as specified prior to shipment. The pressure transmitters supplied on the Hybrid have an accuracy rating of +/- 1.0 of full range. See the cut sheets in Section 4. Calibration certificates are not standard. They can be requested from the transmitter supplier - additional cost and increased lead time will apply.

8 SECTION 1 Aerzen Blower Model D62S Performance Data Bill of Material General Arrangement Drawing Aerzen USA Project: SO Customer: Birch Bay Water & Sewer District Purchase Order No SECTION 2 Hybrid Blower Literature SECTION 3 Hybrid Blower Package Accessories SECTION 4 Hybrid Blower Controls Project: Sewer - CIP WWTP Aeration Basin Upgrades SECTION 5 Motor Details Motor Data SECTION 6 Corrosion Protection/Paint Spec SECTION 7 Testing SECTION 8 Startup Report

9 SECTION 1

10 CUSTOMER INFORMATION CUSTOMER CUSTOMER PO # PROJECT NAME PACKAGE DESCRIPTION EQUIPMENT IDENTIFICATION BLOWER MODEL # D 62 S QTY. (3) PACKAGE DESCRIPTION DISCHARGE CONNECTION TYPE INLET CONNECTION TYPE MOTOR CONDUIT LOCATION TOTAL PACKAGE WEIGHT DOCUMENTATION GENERAL ARRANGEMENT DRAWING MOTOR CABLE ROUTING GB IA OPERATIONS & MAINTENANCE MANUAL G4-007 WARRANTY TERMS & CONDITIONS PERFORMANCE DATA MEDIUM INLET CAPACITY INLET CAPACITY INLET PRESSURE DISCHARGE PRESSURE INLET TEMPERATURE DISCHARGE TEMPERATURE NOMINAL BLOWER SPEED BLOWER SHAFT MOTOR RATING MOTOR SPEED SOUND PRESSURE LEVEL * MOTOR/VFD SPEED Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Service Hotline (800) aerzen@aerzenusa.com website Birch Bay Water & Sewer District Pressure Unit w/ Enclosure 150# ANSI Discharge Connection No Inlet Connection F3 Conduit Box lbs. A2-001-USA DATE Aerzen Job # Page 0-Jan-00 SO of 3 ICFM SCFM PSIA PSI 7 7 F F RPM BHP HP RPM db(a) Hz * measured in free field at 3 foot distance from the outline of the unit (tol. +/- 2 db(a)) Tolerance on Power & Flow is +/- 5% Job Specific Data Package Revision Letter Sewer - CIP WWTP Aeration Basin Upgrades - SERIAL NUMBERS AIR -

11 Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Service Hotline (800) website CRITICAL INFORMATION / NOTES Job Specific Data Package DATE Aerzen Job # Page 13-Feb-15 SO of 3 Revision Letter - 1 PRIOR TO SHIPMENT - AERZEN DOES THE FOLLOWING Removes V-Belts from the motor sheave and wraps them around the blower sheave Locks the motor hinge plate Fills both bearing compartments with Delta - Lube 06 2 LIFTING PACKAGE Without Sound Enclosure: lifting eye holes in the corner of the base frame With Sound Enclosure: lifting through slots in base with fork lift 3 READ OPERATION MANUAL FOR INSTALLATION INSTRUCTIONS Call Aerzen After-Sales / Service if you have any questions 4 AT COMMISSIONING - CUSTOMER / CONTRACTOR IS TO Check oil level (refer to operations manual) - and adjust if necessary Anchor the base or sound enclosure Make grounding connections Connect motor cable per Aerzen Drawing IA Verify correct rotation of motor (counter-clockwise, looking at drive shaft) Remove locking device from motor pivot plate Reinstall V-belts 5 ALL CUSTOMER PIPING TO BE INDEPENDENTLY SUPPORTED 6 Recommended MINIMUM clearance at front and rear of package for "normal" (i.e. inspect machine, change oil, replace belts, etc.) maintenance is 30 inches.

12 ITEM # QTY Date Page 0-Jan-00 SO of Delta Hybrid Stage D 62 S 2 1 Electric Motor 75HP, 365TS, TEFC, 3600rpm, 3/60/460, F3, NEMA prem, shaft grounding ring, insulated bearing-drive end, Thermostats, routine test 3 1 Combination Base Frame / Silencer DN / Sound Enclosure (S.E.) w/ AERtronic Inlet Filter / Silencer Assembly Discharge Connection Housing Filter Element * Drive Belts * One-way Valve EPDM Flap ** Expansion Joint - Discharge 8" 150# ANSI Flange ** X08EG 50 2 Clamps for Discharge Connection for Rubber Exp. Joint Safety Relief Valve 1050 mbar ** Instrumentation AERtronic - Baldor 1 Inlet Pressure Transducer limit setpoint - 20 "H Discharge Pressure Transducer limit setpoint PSI Discharge Temperature Transmitter limit setpoint - 20 F Oil Temperature Transmitter limit set point 240 F Unloading Valve (optional) Not Installed S.E. - Ventilation Fan Electric Fan Motor Sheave Bushing Motor Sheave mm Blower Sheave mm Vibration Isolators Safety Relief Valve Hose Electrical Panel Wiring Diagram No Oil Drain Valve (in service kit) Oil Drain Hose (in service kit) SPARES - SHIPPED LOOSE 3 air filter set of v-belts gal oil container set of sheaves ON SITE SERVICES 1 trip, 2 days - installation inspection, startup & testing 1 trip, 1 day - training RECOMMENDED SPARE PARTS * on hand items ** 2-5 year recommended items NOTE(S): Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Service Hotline (800) aerzen@aerzenusa.com website BILL OF MATERIAL for GB DESCRIPTION Always reference the blower s/n & the Aerzen Job # (if known) when ordering spare parts Job Specific Data Package Aerzen Job # Revision Letter * PART #

13 ANCHORING HOLE D 62 S - DELTA HYBRID DN-200 PRESSURE w/ S.E. GROUNDING CONNECTION FLANGED DICHARGE CONN. (F3 MOTOR) MODEL SPACE 1 :1 GB /2

14 Aerzen D 62S Performance Curves Standard ASME Conditions 2,600 D 62S Flow vs. Speed 6.5 psig 2, psig 14.5 psig Flow (SCFM) 1,600 1, Standard (ASME) Inlet Conditions: T1 = 68F P1 = PSIA RH = 36% Speed (RPM) 2,600 D 62S Flow vs. Power 6.5 psig 2, psig 14.5 psig Flow (SCFM) 1,600 1, Standard (ASME) Inlet Conditions: T1 = 68F P1 = PSIA RH = 36% Power (bhp)

15 Aerzen D 62S Performance Curves Standard ASME Conditions D 62S Blower Shaft Power vs. Speed psig psig Blower Shaft Power (bhp) psig Standard (ASME) Inlet Conditions: T1 = 68F P1 = PSIA RH = 36% Speed (RPM) D 62S Discharge Temp vs. Speed psig 10.5 psig 14.5 psig Discharge Temp (DegF) Standard (ASME) Inlet Conditions: T1 = 68F P1 = PSIA RH = 36% Speed (RPM)

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17 SECTION 2

18 One step ahead. elta HYBRID P a c k a g e s Delta Hybrid Volume flows from 110 m3/h to 5800 m3/h (65 to 3,400 cfm) Pressures to 22 psig (1500 mbar) Vacuum to 21" Hg (-700mbar) Energy-efficient Reliable Compact Quiet

19 Rotary Lobe Compressor The Rotary Lobe Compressor is the result of a synergy between the rotary lobe blower and the screw compressor technologies. The Delta Hybrid was developed with the focus on increasing energy efficiency and achieving a significant reduction of energy costs and greenhouse gas emissions. Wire-to-process energy usage reduction can exceed 30% over typical positive displacement blowers depending on operating conditions and turndown range. Optimized fluidic design of inlet and discharge ports provides for ideal flow conditions and reduced slippage. Moreover, the belt-driven Delta Hybrid offers the significant advantage of exact sizing: the 90 % 5 % 5 % Average operating costs of an air mover over 10 years: energy initial cost maintenance greatest advantage comes from the energy that does not need to be used. A 5% excess in volume flow corresponds to a 5% higher energy use. Further measures that improve energy efficiency: Very wide flow control range with use of a VFD from 25% to 100% Optimized fluidic design of inlet and discharge reduces internal pressure losses Belt drive offers the flexibility to match exactly the required air flow even without the use of a VFD High performance belt drive system with losses under 3% Peak Demand kw Existing PD Blower 30 % Reduction in Peak Demand Rotary Lobe Screw Compressor High efficiency means lower discharge temperature. This reduces aging of downstream membranes or diffusers in synthetic materials. Optimal air flow within the acoustic enclosure brings cool air directly to the intake side and increases compression efficiency Silencer without absorption material and with reduced pressure losses to maintain downstream air free of contamination by absorption material, therefore preventing the loss of efficiency in a diffuser or aeration system.

20 Delta Hybrid Space saving, easy to use and reduced maintenance costs. 3 Easy access to all components with one oil drain/oil fill point. 5 Oil change intervals extended to over 16k operating hours with Aerzen Delta Lube. 1 Easy installation with forklift or pallet jack for placement. 6 Automatic belt tension - No adjustment required. 2 Room-saving, compact, side-by-side installation. 4 Oil level can be observed from the outside. 7 Typical machinery noise average SPL db(a) with acoustic hood. Hybrid Rotary Compressor Stage 3+4 rotor profile with internal compression for low pressure applications. 3+3 rotor profile with twisted rotors and patented pulse charging as well as low squeeze losses. 8 Aerzen patented bearing system extends the bearing life to over 60,000 operating hours (at a differential pressure of 1000 mbar (15 psi). 9 Aerzen 10 Combi-Mount Discharge Silencer eliminates the need for absorption material inside the silencer. For more information, visit

21 The Delta Hybrid has a differential pressure capability of 1.5 bar (22psi). Vacuum operation can now be extended from -500 mbar (- 15"Hg) to -700 mbar (-21"Hg). The Delta Hybrid provides higher reliability under high ambient temperatures, elevated altitudes, and high differential pressures in positive or negative pressure applications; it can now operate safely at discharge temperatures of 160 to 180 degrees C (320 to 356 degrees F). Low noise levels, without absorption material New pulsation reduction in the compressor stage Silencer without absorption materials (patent pending) Additional insulation Inlet cone to further reduce inlet noise (patent pending) Optimized acoustic enclosure Additional advantages of the Delta Hybrid Discharge silencer designed as spark arrestor certified for ATEXapplications PED pressure-vessel guidelines approval (discharge silencer and pressure safety valve), for all machines; ASME VIII U Stamp is a standard option above 15 psig Same pipe conections as Delta Blower Generation 5 The 4:1 turndown adaptibility of the Delta Hybrid enables plants to operate efficiently at minimum capacity without blowing off excess air The broad turndown range keeps the required number of machines to a minimum

22 The accessories that make the difference. Inlet Filter/Silencer Washable filter element. Easily removable internal parts. The filter element is downstream of the silencer for cleanliness. Belt Guard Designed for easy access to the drive. OSHA standard. Instrumentation Standard filter maintenance indicator and p2 gauge Pressure Safety Valve Spring-loaded. Specifically designed for low pressure applications. Mounted vertically downstream of the silencer for longevity. (hidden in photo) Aeromat Start-Up Unloading Valve (Optional) Allows startup of the main motor with no load. The valve is completely self activating and does not need any auxiliary electrical or pneumatic power source. NEMA F3 High Efficiency TEFC Motor Discharge Manifold With integral full bore check valve for low pressure drop. The check valve can be inspected without disconnecting the piping. Hinged Motor Plate Steady alignment and consistent tension provided by the motor weight. No springs needed. Constant high efficiency. Reactive Discharge Aerzen 10 Combi-Mount Silencer Machined support surface for blower. Stiff for installation on vibration isolating mounts. Low pressure drop design. No absorption packing material. ATEX spark arrestor. Vibration Isolating Mounts Rubber-type. Located under the supporting base. No special foundation required. Discharge Flexible Connector Reinforced rubber. Downstream of discharge silencer to reduce transmission of structure-borne noise. For more information, visit

23 Scope of supply Newly designed Rotary Lobe Compressor Discharge silencer integrated in base frame Combined filter and silencer with inlet cone Premium efficiency electric motor High-performance belt drive Hinged motor plate Connecting housing with check valve Pressure safety valve Flexible pipe connector with clamps/or flanged expansion joint Accessories Acoustic enclosure for indoor or for outdoor installation Cooling fan: shaft or electric motor driven Start unloading Aerzen controller AERtronic or gauges Modifications and upgrades ATEX certification ASME, GOST, China License certification All-in-one-solution with integrated starter panel Separate control panel Frequency inverter Other accessories on request Aerzen controller AERtronic The new Aerzen AERtronic controller is based on a modular design approach and offers a solution tailored to each individual application. The controller includes an intuitive touch screen, the base module as well as application dependent add-on modules. All measured operating data is retrievable and parameters adjustable in a user-friendly menu structure. The base unit used across the Aerzen product range includes the following features: processor unit, oil level control, inlet and discharge pressure, motor temperature and speed, three free digital inputs, a relay output, and bus communication interface with control panel and expansion modules. The expansion module offers three digital inputs and three relay outputs as well as inputs for temperature and pressure measurements (for example, oil temperature, compressor outlet temperature, oil pressure). Additional digital inputs, relay outputs, Pt 1000 and analogue inputs and outputs for pressure or temperature control with use of a VFD, as well as bus interface for communication with a master controller or other systems and for data communication can be provided with additional application-related expansion and special modules.

24 Nomenclature: Performance data Example: D 62 S Style: H = high differential pressures to 1500 mbar (22 psi) S = short, differential pressures to 1000 mbar (15 psi) L = long, differential pressures to 800 mbar (12 psi) Max. Volume flow in m³/min (approx.) Rotary Lobe Compressor Positive pressure Size Differential pressure Volume flow Motor power Noise pressure level * max. mbar max. psi max. m³/h max. cfm max. kw max. HP max. db(a) D 12 H D 12 S D 17 L D 24 H D 24 S D 28 L D 36 H D 36 S D 46 L D 62 H D 62 S D 75 L D 98 S D 98 H * Machine emitted noise with acoustic enclosure and with connected and insulated piping, tolerances ± 2 db(a) Vacuum Size Differential pressure Volume flow Motor power Noise pressure level * max. mbar in. Hg max. m³/h icfm max. kw HP max. db(a) D 12 S , D 17 L D 24 S D 28 L D 36 S D 46 L D 62 S D 75 L D 98 S * Machine emitted noise with acoustic enclosure and with connected and insulated piping, tolerances ± 2 db(a) For more information, visit

25 Dimensions and weights Size Width A Depth B Height C Nozzle size DN Weight * mm in. mm in. mm in. (mm) (in.) approx. kg approx. lbs D 12 H / S D 17 L D 24 H / S D 28 L D 36 H / S D 46 L D 62 H / S D 75 L D 98 H / S Dimensions expressed, not binding * Weight without motor C Designed for side-by-side installation. Aerzen means optimal, reliable, trouble-free compression. Aerzen's modular blower packages have been offered since the 1960s. Aerzen Delta Blower packages have been in successful operation since the 1990s. In 2011, Aerzen began offering a single-stage high-speed turbo blower up to 400hp / 2500cfm. Whatever your application and installation requirements, be sure to consider Aerzen. B A Aerzen USA is a certified LEED Gold, Green facility Aerzen USA 2M1011 Printed in U.S.A. Printed on recycled paper with vegetable inks. Aerzen USA 108 Independence Way Coatesville, PA Phone: (610) Fax: (610) Service Hotline: (800) inquires@aerzenusa.com Atlanta: (770) Houston: (281) Aerzen Canada Phone: (450) info@aerzen.ca Aerzen Mexico Phone: (728) ventosa@aerzen.com.mx

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35 SECTION 3

36 DELTA Hybrid Combination Base - Discharge Silencer Description: Combination base - discharge silencer Base/discharge silencer includes three-chamber reactive silencer built as a pressure vessel, stage mounting-flange with studs, discharge connection with integrated check valve, hinged motor plate, entirely supported on vibration isolating feet. The silencer is also free of any absorption material that would break down over time. The silencer is designed as an ATEX Spark Arrestor, contact Aerzen for certification details. Materials of construction: Silencer: Pressure vessel quality carbon steel S 235 JR (St 37-2) equivalent to ASTM A 283 Grade B Pressure vessel code: PED (European directive) PED AD 2000, DGRL 97/23/EG with consideration given to static and dynamic stress (fatigue resistance) Maximum operating temperature: 200 ºC (392 ºF) Maximum operating pressure:1.7 bar gauge (25 psig) Test pressure: 3.1 bar gauge (45 psig) Shell wall thickness: depending on size: 6mm (1/4 ) for DN mm (1/2 ) for DN-250 & DN-300 Performance: Pressure drop of the entire Base-Silencer with connecting housing and check valve, at the maximum allowable flow is 35 mbar (0.5 psi). This difference in pressure is accounted for in the power calculations of the Delta Hybrid package. Combination Base Discharge Silencer DN-100 & DN-125 G-3" Connection for vertical Pressure Relief Valve (PRV) Connecting Housing Discharge Connection Mount (Sleeved Connection Shown) Mounting Flange DN-100 & DN-150 Surface Finish Rz 100 DN-80 PN 16 Square Flange Connection for optional Start-Unloading Valve (AEROMAT) Vibration Isolationg Feet Grounding Lug Hinged Motor Plate (Hidden) Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Combination Base Frame Silencer Delta Hybrid Date Doc # Page 02/12/2015 H revision A 1 of 3

37 Combination Base - Discharge Silencer DN150 DN-125 Connection for vertical Pressure Relief Valve (PRV) DN-100 Connection for optional Start-Unloading Valve (AEROMAT) (Hidden) Connecting Housing Mounting Flange DN-150 Surface Finish Rz 100 Discharge Connection Mount (Sleeved Connection Shown) Vibration Isolationg Feet Grounding Lug Hinged Motor Plate (Hidden) Combination Base - Discharge Silencer DN-200 DN-125 Connection for vertical Pressure Relief Valve (PRV) DN-150 Connection for optional Start-Unloading Valve (AEROMAT) (Hidden) Connecting Housing Mounting Flange DN-200 Surface Finish Rz 100 Discharge Connection Mount (Sleeved Connection Shown) Vibration Isolationg Feet Grounding Lug Hinged Motor Plate (Hidden) Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Combination Base Frame Silencer Delta Hybrid Date Doc # Page 02/12/2015 H revision A 2 of 3

38 Combination Base - Discharge Silencer DN-250 DN-150 Connection for vertical Pressure Relief Valve (PRV) DN-150 Connection for optional Start-Unloading Valve (AEROMAT) (Hidden) Connecting Housing Mounting Flange DN-250 Surface Finish Rz 100 Discharge Connection Mount (Sleeved Connection Shown) Vibration Isolationg Feet Grounding Lug Hinged Motor Plate (Hidden) Combination Base - Discharge Silencer DN-300 Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Combination Base Frame Silencer Delta Hybrid Date Doc # Page 02/12/2015 H revision A 3 of 3

39 DELTA HYBRID Pressure Inlet Filter/ Silencer DN DN 300 PERFORATED STEEL SUPPORT ABSORPTION MATERIAL QUICK RELEASE LATCH FILTER ELEMENT AIRFLOW AIRFLOW AIRFLOW AIRFLOW REMOVABLE LID HYBRID STAGE MOUNTING FLANGE AIRFLOW CONNECTION FOR FILTER MAINTENACE INDICATOR Description: Combination dry air intake filter and absorption type silencer with filter element located downstream from the silencer chamber. The filter element is arranged, looking in direction of flow, directly upstream of the blower stage and protects the Hybrid Stage from wear as a result of dust particles carried along in the air current. Materials of construction: Casing: Powder coated (RAL# 5001) Carbon Steel Maximum operating data: 60 o C (140 o F) and 70 mbar (-2.07 Hg) Removable maintenance lid is held in place with quick release clamps Absorption material: Flame retardant, polyester based urethane foam, grey in color, secured in place with perforated steel Filter element: Thermally bound, food safe, polyester fibers, free of PVC, white in color Filter element mounts with a quick release turn and lock arrangement. Performance: Filtration class: G4 per EN 779 (greater than 90% of synthetic dust particles), equivalent to ASHRAE 52.2 MERV 7 microns) Pressure-drop of the entire silencer and clean filter at the maximum allowable flow: 10 mbar (0.15 psi) Pressure drop filter element: 5 mbar (2 WC) clean, or replace at 45 mbar max. (18 WC) Noise reduction: db mean noise reduction across audible octave bands. DELTAHybrid Inlet Silencer Part Numbers Package Size DN-100 DN-125 DN-150 DN200 DN-250 DN-300 Stage Size D12S/H D17L D24S/H D28L D36S/H D46L D52S D62S/H D75L D98S/H D152S/H Pressure Filter / Silencer Assembly Replacement Filter Element X2 Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Delta HYBRID Pressure Inlet/Filter Silencer DN-100 to DN- 250 Date Doc # Page 1/19/2016 H revision G 1of 1

40 Discharge Connecting Housing DN-100 DN-250 Low Pressure Application Connection Housing (<1000 mbar) FLOW FLOW Connection To Discharge Piping Connection to Discharge Baseframe/Silencer Check Valve Description: Discharge Connecting Housing DN100 through 250 (<1000 mbar) Connection Housing flanged to the outlet of the combination base - discharge silencer It houses a full-bore check-valve: steel embedded in rubber, closes naturally by gravity without use of a spring. The check-valve flap can easily be pulled out for inspection, maintenance or replacement without disconnecting the piping simply by removing the bolts and lifting the cover. Connection to the discharge piping via flexible sleeve connector (standard for air applications) or flange d expansion joint (optional). Materials of construction: Connecting housing: DN 100 to 250 connecting housings are made from EN-GJL-250 cast iron equivalent to ASTM A48 Grade 40B. Pressure code: PED 97/23/ED (European directive), maximum operating data: 200 ºC (392 ºF) and 1.7 bar gauge (25 psig). Check-valve: Seat: metal, flap: steel embedded in EPDM up to 135ºC (275ºF) Option: Silicone rubber. (Low Pressure Applications) DELTA HYBRID Discharge Housing (<1000 mbar) Part Numbers Filter nominal size Stage Designation Discharge Housing (Sleeved) DN-100 DN-125 DN-150 DN-200 DN-250 DN-300 D12S D17L D24S D28L D35S D46L D52S 62S 75L 98S 152S Integral to Base Frame Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Delta Hybrid Discharge Connecting Housing DN-100 DN-250 Date Doc # Page 09/12/11 H revision C 1 of 2

41 DELTAHYBRID SOUND ENCLOSURE COOLING FAN The DELTAHYBRID is equipped with an electric cooling fan when a sound enclosure is supplied. The electric cooling fan uses 460Vac/3ph/60Hz motor. Each DELTAHYRBID cooling fan is wired to a motor starter located in the control panel integrated into the rear of the sound enclosure. For units with or without an AERtronic controller, the cooling fan will be setup from the factory to have the fan start immediately when the main drive motor starts and run-on for 10 minutes after the main drive motor is stopped. If the AERtronic controller is installed, the controller can turn the cooling fan on/off based on ambient temperature inside the sound enclosure to reduce overall power consumption. For controller to manage the cooling fan, an additional RTD must be installed to monitor ambient temperature. Fans Data by Sound Enclosure Size: Sound Enclosure kw (HP) Rated Amps RPM Volume Displaced cfm (m 3 /h) Part No. DN-100/ (0.17) (2400) DN (0.63) (4800) DN (0.96) (7165) DN (1.63) (11300) Material of Blades: Motor Protection: Approvals: Sheet Steel with Black plastic coating or Black plastic (size dependent) each motor is equipped with thermal overload switches and the motor starter monitors for current overload UL1004-1; CSA C22.2 Nr.100; EN60034, CE Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) DELTAHYBRID Sound Encl. Cooling Fans Date Doc # Page 08/11/2015 H revision B 1 of 1

42 Check Valve - DN-100 through DN300 Description: Housed in the connecting housing is a full-bore, steel embedded in rubber check-valve that closes naturally by gravity without use of spring. The check-valve flap can easily be pulled out for inspection, maintenance or replacement without disconnecting the piping by removing the bolts and lifting the cap. Materials of construction: Flap: steel embedded in EPDM up to 149ºC (300ºF) Standard on Low Pressure Connection Housing (< 1000 mbar, 14.5 psig) with option for Silicon Rubber. High Pressure Connection Housing (> 1000 mbar, 14.5 psig) only available with Silicone Rubber embedded in steel Size DN Check Valve Assembly w/ EDPM flap P/N EPDM flap only P/N Check Valve Assembly w/ / Silicone flap P/N Silicone flap only P/N n/a n/a n/a n/a Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Delta Hybrid Check Valve Date Doc # Page 02/12/2015 H revision A 1 of 1

43 CONNECTING HOUSING (BASE FRAME) CLAMPS BACKING RING 3/8" THK. (CARBON STEEL) BOLT HOLES Ø A (Sleeve ID) B (150# ANSI Flange size) C (Length) D (Pipe Engagement) MATERIAL DN-050 DN X02EG DN X04EG DN X04EG DN X05EG DN X06EG X03EG DN X05EG-A DN X06EG-A DN X06EG DN X08EG DN X08EG DN X10EG DN X10EG DN X12EG DN X12EG

44 Delta Hybrid Pressure Relief Valve Description: The Pressure Relief Valve is designed for use with air or inert gasses to protect the Hybrid and its accessories from damage in the event of excessive pressure. It is not to be used as a pressure regulating device. It contains a spring-loaded valve guided by a spindle and surrounded by a protective sheath that is capable of venting the entire volume flow of the blower. In positive pressure machines, it is installed downstream from the Hybrid Stage and before the check valve or any shutoff valve. In vacuum applications, it is installed on the intake side of the stage. SPRING END PLATE SPRING SPINDLE GUIDE BUSHING MAINTENANCE PORT BELL PISTON SEAT QTY DESCRIPTION MATERIAL QTY DESCRIPTION MATERIAL 1 Connection Flange or Thread with Valve Seat Grey Cast Iron 2 Guide Nut Carbon Steel 1 Valve Spindle Carbon Steel 1 Spring Spring Steel 1 Bell Brass 1 Valve Disc / Piston Brass 1 Spring End Plate Carbon Steel 1 Valve Guide / Bushing Brass 2 Hex Nut Carbon Steel 1 Cover Aluminum Technical Data: Maximum Temperature: 200 C (392 F) Conforms to PED 97 / 23 / EG Maximum Pressure: 1.65 Bar (26 PSIG) Valve Characteristic: Proportional Pressure Rise: 10% Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Delta Hybrid Pressure Relief Valve Date Doc # Page 2/12/2015 H revison D 1 of 2

45 DELTA HYBRID Pressure Relief Valves Nominal Package Size Hybrid Designation Valve Size Positive Pressure Valve Connection Vacuum Valve Connection DN-100 D 12S D 12H DN-125 DN-150 DN-200 DN-250 DN-300 D 17L D 24S D 24H D 28L D 36S D 36H D 46L D 52S D 62S D 62H D 75L D 98S D 98H D 152S D 152H DN-80 G-3" External Dn-80 PN 16 Flange DN-125 Dn-125 PN 16 Flange Dn-125 PN 16 Flange DN-150 DN-150 PN 16 Flange DN-150 PN 16 Flange DN-200 DN-200 PN 16 Flange DN-200 PN 16 Flange Maintenance: Periodically inspect for free movement of the valve. While the machine is stopped and the motor locked out, insert flat blade screw drivers into both maintenance ports and lift the valve. Remove the screw drivers and visibly ensure the valve is properly seated. When operated in clean environments, inspect valve either every six months or 1000 run hours, whichever occurs sooner. In dusty conditions, inspect every month. Refer to document G4-002 for complete operating instructions. Aerzen USA Corporation 108 Independence Way Coatesville, PA Tel: (610) Fax: (610) Delta Hybrid Pressure Relief Valve Date Doc # Page 2/12/2015 H revison D 2 of 2

46 STYLE - 2 STYLE - 1 STANDARD MOUNT FAIL SAFE MOUNT Only (1) anchor per foot is required for Standard mounts, anchor each hole ( G ) for Fail-safe mounts. Standard mounts are not recommended for use where negative loads occur, (marine or earthquake zones) use Fail-safe mounts or contact Aerzen for alternates. All vibrations isolators have a natural frequency that will not interfere with the fundamental blower package frequencies. Baseframe Standard P/N Fail Safe P/N Style A (mm) B (mm) C (mm) D (mm) E F (mm) G Maximum Load (mm) Per Foot Recommended Anchor KN Lbf Aerzen P/N DN N/A M , DN-80 DN-100 DN M DN _FS M DN _FS M DN DN-300 N/A M Aerzen USA Corporation 108 Independence Way Coatesville, PA Vibration Isolators G5 Blowers Date Doc # Page Tel: (610) Fax: (610) /17/2014 B revision F Page 1 of 1

47 SECTION 4

48 Operating instructions for Aerzen control system ENGLISH Aerzen - one step ahead AERZENER MASCHINENFABRIK GMBH AS-002 C EN AS-002 C EN Translation of the original instructions 1

49 ENGLISH The INFO page is to be read before commissioning. Any noted instructions and changes are to be implemented. We reserve the right to correct typographical errors and content errors and make revisions related to technical changes. 2 AS-002 C EN Translation of the original instructions

50 Table of contents Front page...1 Instructions on info page...2 Table of contents...3 Installation position Aerzen control system Overview of operating fields STARTING and STOPPING the machine Warning, alarm and cut-off, malfunction Fault registry Opening Main menu Switching AERtronic from LOCAL to REMOTE Service and maintenance Maintenance / service resetting Regulation with PID controller Units conversion from C to F and bar to psi Screen saver and cleaning Module status Timer Parameter Connection of the control system Fault / malfunction messages Alarm and warning messages Maintenance messages Status messages Connection of the Modbus Connection of the Profibus Battery change Technical data INFO page ENGLISH AS-002 C EN Translation of the original instructions 3

51 Installation position / AERtronic AS 300 ENGLISH Modular installation of the control system Operating unit with Touch Panel Beispiel / example 4 AS-002 C EN Translation of the original instructions

52 Aerzen control system AERtronic AS 300 Safety information Commissioning, operation, parametrisation and maintenance of the control system must only be performed by trained personnel. Improper operation may result in property damage and personal injury! General specifications The AERtronic AS 300 is used as a control system for rotary piston machines. The AERtronic is equipped with a color graphic display with a touch screen. At least one basic compact module and additional I/O modules are needed for the overall system. The AERtronic AS 300 is set according to order and includes all operating parameters, such as pressures, temperatures,... During the initial commissioning, deviations from these settings can be carried out The additional handling and operation of the control system is predefined in the display and guides the operator through the menu in a structured manner. The AERtronic AS 300 includes all functions for the starting and shutdown procedure as well as the display and querying of the operating parameters. The AERtronic AS 300 can be used as a display and monitoring unit as well as control of a rotary piston machine. ENGLISH Aerzener Maschinenfabrik reserves the right to make changes, expansions or improvements to this product, hardware and software, as needed. This implies no obligation to update equipment that has already been delivered. AS-002 C EN Translation of the original instructions 5

53 2. Overview of operating fields ENGLISH 1.) Information menu 5.) Tab Pressure ranges 6.) Tab Temperature ranges 7.) Tab additional operating parameters 8.) Tab Service and Setup 2.) Service message optical message for pending service work 3.) START 4.) STOP 9.) Selection keys of the particular display menu within a tab (discharge pressure, intake pressure, discharge temperature, oil temperature, etc.) 10.) Graphical representation 13.) Measured value display 12.) Range indicator of the respective operating parameter 11.) Numerical value display 6 AS-002 C EN Translation of the original instructions

54 Overview of additional operating fields X Previous screen RESET ENGLISH ENTER C Deletes last entry Increase value / scroll up Decrease value / scroll down AS-002 C EN Translation of the original instructions 7

55 3. STARTING and STOPPING the machine 3.1 Ready-to-start condition ENGLISH The machine is ready to start if the following items are satisified. - no warning is active - no shut-down is active - the restart delay has expired. - the starting block is not blocked by many starts/hours If only one condition is not satisified, the machine is not ready to start. Conditions that are not met are displayed in the information menu as an message, warning or shutdown. In order to create the ready-to-start condition, there must be an acknowledgement. Messages M02 Switching cycles exceeded M02 Switching cycles exceeded 8 AS-002 C EN Translation of the original instructions

56 3.2 Maschinen START The machine can be started either locally or remotely, if no warning and / or shut-down and starting block (restart interlock or starts/hour) are active. Pressing the green button in the display starts the machine in the operation mode "local". ENGLISH Discharge pressure 0.00 The starting of the machine is complete if the compressor symbol in the green area no longer flashes. Discharge pressure 1.80 AS-002 C EN Translation of the original instructions 9

57 3.3 STOPPING the machine Pressing the red button in the display stops the machine. ENGLISH Discharge pressure 1.80 Switching off the machine is completed if the compressor symbol in the green area no longer flashes and the symbol Stoppage / OFF is displayed in the green button. Discharge pressure AS-002 C EN Translation of the original instructions

58 4. Warning, alarm and cut-off Discharge pressure The screen flashes yellow if a warning or an alarm has expired. Alarms and warnings do not cause a shutdown of the machine, but prevent restart when the machine is stopped. After the acknowledgement or reset, the screen shows continuous yellow illumination if their is still a malfunction ENGLISH Discharge pressure The screen flashes red if a shutdown has occurred. After acknowledgement or Reset, the screen continuously flashes red if a malfunction is still present. A shutdown always causes the main motor to be switched off. The flashing information button provides detailed information about the malfunction message. Messages A 005 Discharge pressure E 019 Discharge pressure Date and time of the event Note: The cause of the fault needs to be checked and eliminated. Only after that is a restart of the machine advisable. AS-002 C EN Translation of the original instructions 11

59 5. Fault registry All events with data and time are stored in the fault registry. An overview of all alarms, warnings and shutdowns is given in the appendix. ENGLISH Main menu Control system Base load change Timer Display Machine parameters Limit values Service Configuration Service menu Maintenance intervals Fault registry Acknowledge maintenance Hours counter Load factory setting Save factory setting Parameter history 12 AS-002 C EN Translation of the original instructions

60 Fault registry menu A 018 Pressure ratio A 005 Discharge pressure E 019 Discharge pressure E 019 Discharge pressure A 005 Discharge pressure Appearance of an alarm or warning. Appearance of a shutdown Triggered and acknowledged alarm or warning Triggered and acknowledged shutdown ENGLISH E019 Discharge pressure Indicates all available measured values at the time of the event. AS-002 C EN Translation of the original instructions 13

61 6. Opening Main menu ENGLISH Service Air filter Pressure intake filter Breather holes Operating times Operating hours: On-load hours: Idle run. hours: Setup Log in under one of the selections. User Superadmin 14 AS-002 C EN Translation of the original instructions

62 User Logon Enter code confirm Enter User login User Superadmin ENGLISH Main menu Control system Base load change Timer Display Machine parameters Limit values Service Configuration AS-002 C EN Translation of the original instructions 15

63 7. Switch AERtronic from LOCAL to REMOTE Main menu ENGLISH Control system Timer Machine parameters Base load change Display Limit values Service Configuration Control system menu Regulation Miscellaneous Communication Depending on the access code, the display of the menu items may vary. 16 AS-002 C EN Translation of the original instructions

64 General control menu Operation mode: Cont. operation Remote load / idle: Off Remote on / off : Automatic restart: Digital No The lock signifies that remote operation has been selected. Starting and stopping the machine using these keys is NOT possible. Selection of operating location for Start-/ Stop Off Control panel Digital Corresponding Digital input "Remote On/Off" Modbus/Profibus Corresponding bits via the communication ENGLISH Comment: In the "Modbus / Profibus" selection, the location lock (locks) appears only after the "Remote ON / OFF" enable bit is set (byte 2, bit 7) AS-002 C EN Translation of the original instructions 17

65 8. Service and maintenance The operator is informed about maintenance to be performed or a service. The information is displayed with a flashing background screen and occurs 100 hours before the actual service interval. Pressing the information button yields the exact information about the pending maintenance or the service. ENGLISH Note: The maintenance and service information is to be regarded as a supplementary assistance. What is binding for any maintenance or service is the information in the operating manual of the assembly or machine stage in question. Discharge pressure 18 AS-002 C EN Translation of the original instructions

66 Messages W0 1 Maintenance interval Air filter: After the acknowledgment of the maintenance or service, the background is continuously yellow. The actual resetting of a maintenance interval occurs in the service menu under the menu item "Acknowlege maintenance", as long as the message remains active and the information button is flashing. ENGLISH On the Service tab, the times until the next maintenance are displayed on the first page. Obtain additional information by pressing on the interval with the blue background. Service V-belt 500h Coupling 1000h Pressure valve 1500h V-belt Service in 500h Check condition of V-belt, replace if necessary Check orientation of pulleys, correct as needed AS-002 C EN Translation of the original instructions 19

67 9. Reset maintenance or service After conducting the maintenance, it must be reset in the "Acknowledge Maintenance Interval" menu and thereby cause the service counter to be restarted. ENGLISH Main menu Control system Timer Base load change Display Machine parameters Limit values Service Configuration Service menu Maintenance interval Fault registry Only visible for Aerzen technical personnel! Acknowledge Hours counter Load factory setting Save factory setting Parameters history Maintenance acknowledgment menu Maintenance counter air filter: Maintenance counter pr. filter cartridge: Reset Reset Maintenance operations that must be reset have a yellow background. When "Reset" is pressed, the service counter is restarted. Maintenance counter for coupling: Maintenance counter for pressure valve: Reset Reset Caution: Also maintenance that is not yet pending can be reset by pressing the "Reset" key. Note: The appearance and resetting of the maintenance and service intervals are stored in the history memory along with the date and time and can be viewed at any time by Aerzen service personnel. 20 AS-002 C EN Translation of the original instructions

68 10. Regulation with PID controller Basic information: The AERtronic AS 300 is equipped with a software PID controller. It is used to control the suction pressure or discharge pressure. The actual value is read in at the analog input for the system pressure. The set value for the pressure can either be predefined over the operation panel or the communication Modbus/Profibus. A corresponding analog output (for example pressure control) then predefines the rotational speed for a frequency converter. An external speed pre-set is also possible with an analog input (ext. predefinition) or over the communication Modbus/Profibus, if available and configured. ENGLISH Opening the control parameters Control system menu Regulation Miscellaneous Communication Regulation menu Set pressure: Idling pressure/max. pressure: Speed setting: Pressure regulation: Auto Discharge side Set value for the PID controller. The control output attempts to keep the system pressure at this value. Switching between Automatic and Manual mode and external speed preset Selection of the control system on the intake and discharge side If the system pressure exceeds this value, the machine is switched into idling mode if there is a load/idle control. If the pressure falls below the set pressure, the system switches back into operation under load. (Refer also to Run/Shutdown mode) AS-002 C EN Translation of the original instructions 21

69 Regulation menu Minimum regulation limit ENGLISH P-portion: I-portion: D-portion: Limits the controller output to this set value. Normally is not needed because the minimum rotational speed on the FU must be limited Control parameters: P-portion = Controller faster I-portion = Controller slower D-portion = Controller faster with pressure regulations usually 0% 22 AS-002 C EN Translation of the original instructions

70 Controller in manual mode If the PID controller is set to manual mode in the controller parameters, the selected value can be changed by using the shown cursor buttons. Selected value ENGLISH Change of the selected value or the speed in manual mode. Cursor keys appear only after the engine starts up. Load/idle and cut-off/continuous mode If the machine is equipped with load/idle valves, these can be controlled by the AERtronic AS 300. The configured digital output (load valve) takes over the control of the interphase transformer and discharge magnet valve. In idle mode the volume flow on the input side of the compressor is reduced by a suction valve and the pressure side is balanced by a discharge valve. The machine always switches to idle mode while starting and stopping and during stoppages. AS-002 C EN Translation of the original instructions 23

71 ENGLISH Machine parameters menu Maximum machine pressure: Restart interlock: After the start command and expiration of the set run-up time, the machine switches into operation under load. Run-up time: Star/delta switchover time: The system pressure is used as the actual value for the load/idle control. If it exceeds the limit value for Idle pressure the machine automatically switches to idle mode. If the system pressure falls below the Set pressure it switches back to load mode. The parameter minimum idle time in the machine parameter menu causes a delay switching between load and idle and prevents quick switches between loads. 24 AS-002 C EN Translation of the original instructions

72 The load/idle mode can also be controlled externally by a configured digital input (remote load/idle) or the communication Modbus-/Profibus. General control menu Operating mode: Remote load / idle Remote On / Off Automatic restart: Power on operating mode Digital Off No Load/idle mode depends on: From system pressure Digital Digital input (Signal 1 load mode) Modbus-/Profibus bit in the communication ENGLISH Cut-off mode If the cut-off operation mode is active the machine additionally switches to standby. It also switches off the main motor and the AERtronic AS 300 remains keyed. This is indicidated by the standby symbol. To prevent the main motor from being switched on and off all the time there is a Runon time in the machine parameter menu. Only after the run-on time is expired and the machine switches to idle mode it is switched to standby. If the system pressure falls below the set pressure the machine is restarted from standby mode and takes over the load mode. Ctinuous mode If the continuous operation mode is active, the machine switches to idle mode but does not enter standby mode. AS-002 C EN Translation of the original instructions 25

73 11. Conversion of the units C to F and bar to psi ENGLISH Main menu Control system Timer Base load change Display Machine parameters Limit values Service Configuration Display menu Limits trend graph Cleaning display Units Screen saver Units menu Conversion from bar to psi Pressure unit: BAR Temperature unit: C Conversion from C to F 26 AS-002 C EN Translation of the original instructions

74 12. Screen saver and cleaning Cleaning of the screen Main menu ENGLISH Control system Base load change Timer Display Machine parameters Limit values Service Configuration Display menu Limits trend graph Cleaning display Units Screen saver The cleaning is only possible when the machine is switched off. The menu item "Cleaning display" is suppressed when the machine is running. AS-002 C EN Translation of the original instructions 27

75 ENGLISH Cleaning display menu Attention: After starting this function, the control system cannot be operated further for 1 minute. Start After pressing Start, the screen is blocked for one minute and cleaning can be started. The time remaining is displayed on the screen. The cleaning should be done with a soft cloth. Aggressive and abrasive polishing compounds must not be used, because in this case the display can sustain damage. Screensaver Screen saver menu Screen saver: Screen saver delay: Brightness standard: Brightness screen saver: Yes With the selected screensaver, the display goes into screensaver mode after the expiration of the set time. Brightness in normal mode Brightness when the screensaver is active 28 AS-002 C EN Translation of the original instructions

76 13. Module status The Basic Compact and Smart (EMO) modules do not have LEDs and therefore also have no status message of the digital inputs and outputs. For this reason, the "Module status" screen indicates the current status of the digital inputs and outputs. ENGLISH 3 x Controlled inputs and activated, controlled outputs are shown in green. EMERGENCY OFF Motor protection Main motor Remote On / Off Start main motor Line protection or frequency converter Malfunction (Motor Off) Motor protection Oil mist separator Ready to start Warning / Alarm Comment: The assignments of the digital inputs/outputs listed above relate to the standard version. The specific version can be taken from the respective circuit diagram. AS-002 C EN Translation of the original instructions 29

77 14. Timer ENGLISH Eight time-switch channels are available. The control system evaluates the channels of the series. On a weekday activated in the time-switch channel, the system is switched on or off corresponding to the set activation and cut-off time. The activation time must always be before the cut-off time. If the system is to run round the clock, activation and cut-off times must be set to 0:00 or to the times 0:00 and 24:00 and the desired weekdays must be activated. Main menu Control Base load change Timer Display Machine parameters Limit values Service Configuration Timer menu Timer: Off Date: Time: Timer menu Channel 1: Off Mon off Tue off Wed off Thu off Fri off Sat off Sun off Switch-on time: Switch-off time: 30 AS-002 C EN Translation of the original instructions

78 15. Parameter 15.1 Machine parameter menu Menu path: Main menu --> Machine parameters Parameter Range of values / basic settings / notes Password Max. machine pressure default : --,-- bar Limits the set value and discharge pressure to this value ENGLISH Restart interlock s / default: 10 s After the main motor stops, the machine is ready to start again only after this time expires Run-up time 3-30 s / default: 6 s After expiration of the run up time, the "Delta" output is activated if it is configured. In this time, the regulation is deactivated and the machine is in the unloaded state. Activatio of the run up time when main motor is started. User Star/delta switching time msec / default: 40 msec Equalizes the actuation and cut-out times of the star/ delta contactors Superadmin Acceleration time s / default: 1 s The startup time + acceleration time yield the release for the regulation. The machine switches into operation under load or regulates the system pressure using the speed. However, the machine requirements must be met for this. Refer also to PID Regulation chapter Min. motor run time min / default: 2 min After the main motor is started and cut-off mode is activated (Control system --> Miscellaneous), the machine does not switch into Standby mode until the min. motor run time is expired. Requirement: Idling mode and expired run-on time. Min. idling time s / default: 2 s Prevents the switching between idling mode and operating under load from occurring too quickly. Only after this time expires can the machine be switched back into operation under load. Min. run-on time s / default: 30 s When cut-off mode is activated (Control system --> Miscellaneous), the machine switches into Standby mode after this time expires (main motor off). Comment: After main motor start, the "min motor run time" must first have expired. AS-002 C EN Translation of the original instructions 31

79 Cut-off time s / default: 5 s After a Stop command, the main motor is switched off only after expiration of this time. During this time, the machine is in the unloaded state if there is Idling/Full load regulation. ENGLISH Oil pressure delay Oil pressure 2 delay s / default: 10 s After machine start, the monitoring of the oil pressure is activated only after this time expires. Precisely during frequency inverter operation is an adjustment possibly necessary here s / default: 10 s Oil pressure delay of the 2nd stage. Same function as parameter "Oil pressure delay" User User Switching cycles switching cycles / hour / default: 6 / h The main motor starts per hour are counted and prevent the machine from starting when the limit is exceeded. Pressure rate monitoring: Yes / No / default No When "Yes" is selected, the pressure rate of the machine will also be monitored. A corresponding screen is shown under the pressure measurement values. Superadmin Average ambient pressure mbar / default 1000mbar The placement height of the machine can be adjusted here Superadmin Fan Run-on time 0-60 min / default 0 min Run-on time of the fan after system stoppage. The assigned digital output is "Fan". 32 AS-002 C EN Translation of the original instructions

80 15.2 Control menu The control system menu comprises the following submenus: - Control - Communication - Miscellaneous Regulation menu Menu path: Main menu Control Regulation Parameter Range of values / basic settings / notes Parameter Set pressure bar default : 0.5 bar - Set value for PID regulator - If the system pressure falls below this value, the machine switches into operation under load, the contact of the digital output "On-load" closes, and the solenoid valves are triggered. - If the system pressure falls below this value, the machine starts from Standby mode. The parameter "Cut-off mode" must be selected under "Control system Miscellaneous". User ENGLISH Idling pressure/ Max. pressure -1.0 Maximum machine pressure (machine parameters) default : 0.7 bar - If the system pressure exceeds this value, the machine switches into idling mode when there is load/idling regulation. The contact of the digital output On-load opens. - If the system pressure exceeds this value, the analog speed output Pressure regulation is set to 0. User Speed setpoint Auto / Manual / External default : Auto - Auto: The internal PID controller is in Automatic mode and with the aid of the analog speed output Pressure regulation attempts to keep the system pressure constant. See also parameter Set pressure - Manual: The internal PID controller is in Manual mode. After the start and run up of the machine, the speed can be changed using the cursor keys in the Selected value screen. - External: The speed can be preset via an externally active 4-20mA signal. To do this, an analog input must be configured as Ext. allocation. In this context, 4mA=0%=min. speed and 20mA=100%= max. speed. User Pressure regulation None / discharge side / intake side default : None - None: The PID controller is inactive - Discharge side: The internal PID controller regulates the discharge side of the machine. - Intake side: The internal PID controller regulates the intake side of the machine. The setting is used with vacuum machines. User Minimum Minimum regulation limits Minimum regulation limits default : 0% This value limits the speed at the bottom end. As a rule, this function does not have a use, because a limitation is forced on the minimum speed in the frequency converter. User AS-002 C EN Translation of the original instructions 33

81 P-portion 0 100% default:50% The P-portion represents the proportional part of the PID controller. If this parameter is increased, then the step response (controller output or speed) with an actual value change (system pressure) is accordingly higher. The P-portion is thus only proportional to the actual value signal. P-portion = Controller response = Controller faster User ENGLISH I-portion 0 100% default:20% The I-portion represents the integral portion of the PID controller. If this parameter is increased, then the control speed of the controller output (speed) also increases when there is a regulation variance (fference between set pressure and system pressure). The I-portion is thus integrated in terms of timing with the controller output as long as there is a regulation variance. I-portion = regulation speed = controller faster User D-portion 0 100% default:0% The D-portion represents the differential portion of the PID controller. The D-portion does not react to a regulation variance (difference between set pressure and system pressure), rather, only to its rate of change. Thus, the faster the system pressure changes, the higher is the controller output (speed). With normal pressure controllers, this D-portion is usually zero. D-portion = Controller response to changes in actual value = Controller faster User Switch-on temperature Heating C default : 0 C If the Ambient temperature drops below this set value, the contact of the digital output Heat is closed and the heat is thereby switched on. This function is active both the when the machine is stopped and during operaiton. The following parameters absolutely must be set: - An analog input must be parameterized to "ambient temperature". - A digital output must be parameterized to Heat. User Cutoff temperature Heating C default : 10 C If the ambient temperature increases above this set value, the contact of the digital output Heat is opened, and the heat is thereby switched off. Refer also to Heat switch-on temperature User Switch-on temperature Fan C default : 40 C If the ambient temperature increases above this set value, the contact of the digital output fan is closed, and the fan is thereby switched on. This function is active both the when the machine is stopped and during operaiton. The following parameters absolutely must be set: - An analog input must be parameterized to "ambient temperature". - A digital output must be parameterized to Fan. User Cutoff temperature Fan C default : 30 C If the ambient temperature drops below this set value, the contact of the digital output Fan is open and the ventilation is thus switched off. Refer also to Fan switch-on temperature User 34 AS-002 C EN Translation of the original instructions

82 Communication menu Menu path: Main menu Control Communication Parameter Range of values / basic settings / notes Parameter Address 0 31 default : 1 User Record Speed setpoint Standard / Modbus default : Standard - Standard: Protocol for the transfer of the firmware - Modbus: Modbus-slave-RTU protocol with RS485 interface / 9600 / / / default : User User ENGLISH Miscellaneous menu Menu path: Main menu Control Miscellaneous (General control) Parameter Range of values / basic settings / notes Parameter Operating mode Cut-off mode / continuous mode default : Cut-off mode - Continuous mode: Machine switches just into operation under load and idling and not into standby mode - Cut-off mode: In idling mode, the machine switches into standby mode after the expiration of a the after-run time (main motor off) User Remote load / idling Off / Digital / Modbus Profibus / RS485 Intern default : Off - Off: The on-load / idling regulation is determined by the system pressure and the limit values Set pressure and Idling pressure. - Digital: The operation under load is determined as a function of the digital input Remote on-load/idling. With the logic NO, the operation under load is executed with signal value 1. - Modbus/Profibus: The on-load/idling operation depends on the communication. Two bits are needed for this purpose. One bit as basic enabling 1 and the other bit for on-load operation 1 and idling 0. See additional Modbus or Profibus list - RS485/internal: Only for integrated control User Remote On / Off Off / Digital / RS485 Profibus default : Off - Off: The starting and stopping of the machine is done locally with the keys on the control module - Digital: The machine is started and stopped as a function of a digital input Remote On/Off. With the NO logic, the machine is started with a 1 signal - Modbus/Profibus: Starting and stopping is done via the communication. Two bits are required for this. One bit as basic enabling 1 and the other bit for starting 1 and stopping 0. See additional Modbus or Profibus list User AS-002 C EN Translation of the original instructions 35

83 Automatic Restart No / yes default : No - Yes: When there is a control voltage outage, the machine is automatically started after power is restored and the expiration of the restart delay. User ENGLISH Restart delay s default : 60s After expiration of the set time, the machine is automatically restarted if the parameter Automatic Restart is set to Yes. User 36 AS-002 C EN Translation of the original instructions

84 15.3 Service menu The control system menu comprises the following submenus: - Maintenance intervals (visible as User) - Acknowledge maintenance (visible as User) - Fault registry (visible as User) - Hours counter (visible as ) - Load factory setting (visible as ) - Parameter history (visible as ) - Save factory setting (visible as Superadmin) Maintenance intervals menu Menu path: Main menu Service Maintenance intervals ENGLISH Parameter Range of values / basic settings / notes Parameter Maintenance interval Intake filter Maintenance interval press. Filter element h default : 0 h Check filter soiling and replace filter element as needed h default : 0 h Earlier when the pressure loss is increasing. Maintenance interval Supply/exhaust air Maintenance interval V-belt Maintenance interval Coupling Maintenance interval Pressure valve h default : 0 h Check intake/exhaust openings of the sound enclosure and clean as required h default : 0 h Check condition of V-belt and replace if necessary. Check alignment of V-belt. Correct as needed h default : 0 h Check coupling pins, compression sleeves and replace if necessary. Check coupling alignment and correct as required h default : 0 h Check operation of pressure valve. Maintenance interval Lubricating oil h default : 0 h Change lubricating oil Maintenance interval Oil filter h default : 0 h Replace oil filter Maintenance interval Check valve h default : 0 h Check the check valve for wear and leaks. Maintenance interval Oil separator h default : 0 h Clean cooling fins, wire mesh and oil mist separator. Maintenance interval Water cooling h default : 0 h Clean heat exchanger / water cooling pipe bundle AS-002 C EN Translation of the original instructions 37

85 Maintenance interval Steam trap h default : 0 h Check and clean steam trap. Maintenance interval 1. Maintenance h default : 0 h See operating and installation manual of the stage or assembly. ENGLISH Maintenance interval Main inspection Maintenance interval Motor h default : 0 h Main inspection / Maintenance check / Replacement of spare parts and wear parts. Review of the complete machine h default : 0 h Bearing, relubrication (grease types), condensate drain 38 AS-002 C EN Translation of the original instructions

86 Acknowledge maintenance menu Menu path: Main menu Service Acknowledge maintenance (maintenance acknowledgement) Parameter Range of values / basic settings / notes Parameter Maintenance counter Intake filter Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. User Maintenance counter press. Filter element Maintenance counter Supply/exhaust air Maintenance counter V-belt Maintenance counter Coupling Maintenance counter Pressure valve Maintenance counter Lubricating oil Maintenance counter Oil filter Maintenance counter Check valve Maintenance counter Oil separator Maintenance counter Water cooling Maintenance counter Steam trap Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. User User User User User User User User User User User ENGLISH AS-002 C EN Translation of the original instructions 39

87 ENGLISH Maintenance counter 1. Maintenance Maintenance counter Main inspection Maintenance counter Motor Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to zero and does not start over. The first maintenance is performed only once. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. Reset Blue Resetting the maintenance counter is not required Yellow The maintenance counter is reset to the specified value under "Maintenenance interval" reset and starts over. User User User Fault registry menu Menu path: Main menu Service Fault registry Up to 100 malfunction and maintenance messages can be stored in the fault registry. For each message are stored the message number, the message text, the time stamp and a yellow warning or red malfunction symbol. Pressing on the corresponding symbol opens an additional information page in which all values at the time of the occurrence are stored. Detailed information is available in the fault registry chapter. 40 AS-002 C EN Translation of the original instructions

88 Hours counter menu Menu path: Main menu Service Hours counter Parameter Range of values / basic settings / notes Parameter Operating hours Current status of the operating hours Indicates the current operating hours. Pressing on the hours opens an input window and the value can be changed. Load hours Rental machine Current status of the operating hours Indicates the current on-load hours. Pressing on the hours opens an input window and the value can be changed. No / yes default : No - No: No additional operating hours counter for rental machines - Yes: An additional operating hours counter is activated and displayed in the Operating times screen. ENGLISH Rental hours Reset Pressing it makes the rental hours counter reset to zero. AS-002 C EN Translation of the original instructions 41

89 Load factory setting menu Menu path: Main menu Service Load factory setting The configuration stored under Save factory setting can be reloaded via this function. The menu item is shown if the user has logged on as and previously the configuration also had actually been saved. After printing the menu item, the following warning appears: ENGLISH Attention: All previous settings are thereby overwritten The loading of the factory setting can be interrupted by leaving the page or started via the Load button. In this case, the Load factory setting message appears after the loading Parameter history menu Menu path: Main menu Service Parameter history In the Parameter history, all changes of the setting are documented and saved. In addition to the date and time, the designation of the parameter, the original value and new one are saved Save factory setting menu Menu path: Main menu Service Save factory setting This menu item appears only if the user has logged on as Superadmin. After this menu item is pressed, the following warning appears: Save factory setting? The saving of the factory setting can be interrupted by leaving the page or started via the Save button. In this case, the Save factory setting message appears after the saving operation. After the initial save, the button Load factory setting appears in the Service menu 42 AS-002 C EN Translation of the original instructions

90 15.4 Limit values menu Menu path: Main menu Limit values Parameter Range of values / basic settings / notes Parameter Suction pressure warning bar / bar / default : bar Suction pressure warning delay 0 15 s default : 1 s Suction pressure fault Suction pressure fault delay Warning ambient temperature Lo bar / bar / default : bar 0 15 s default : 1 s C default : -10 C ENGLISH Warning ambient temperature Lo delay 0 15 s default : 1 s Warning ambient temperature Hi C default : 40 C. Warning ambient temperature Hi 0 15 s default : 1 s Warning discharge pressure bar / bar / bar default : 1.0 bar Warning discharge pressure delay 0 15 s default : 1 s Discharge pressure fault bar / bar / bar default : 1.2 bar Discharge pressure fault delay 0 15 s default : 1 s Warning discharge temperature Warning discharge temperature delay Malfunction discharge temperature Malfunction discharge temperature delay Oil pressure warning C default : 200 C 0 15 s default : 1 s C default : 210 C 0 15 s default : 1 s bar default : 2.5 bar Oil pressure warning delay 0 15 s default : 1 s Malfunction oil pressure bar default : 2.0 bar Malfunction oil pressure delay 0 15 s default : 1 s Warning oil temperature C default : 50 C Warning oil temperature delay 0 15 s default : 1 s Malfunction oil temperature C default : 60 C Malfunction oil temperature delay 0 15 s default : 1 s AS-002 C EN Translation of the original instructions 43

91 Warning system temperature C default : 0 C Warning system temperature delay 0 15 s default : 1 s ENGLISH Malfunction system temperature Malfunction system temperature delay Suction temperature warning 2 Suction temperature warning 2 delay Malfunction intake temp C default : 0 C 0 15 s default : 1 s C default : 0 C 0 15 s default : 1 s C default : 0 C Malfunction intake temp. 2 delay 0 15 s default : 1 s Warning discharge pressure 2 Warning discharge pressure 2 delay Malfunction discharge pressure 2 Malfunction discharge pressure 2 delay Warning discharge temperature 2 Warning discharge temperature 2 delay Malfunction discharge temperature 2 Malfunction discharge temperature 2 delay Oil pressure 2 warning bar default : 0 bar 0 15 s default : 1 s bar default : 0 bar 0 15 s default : 1 s C default : 0 C 0 15 s default : 1 s C default : 0 C 0 15 s default : 1 s bar default : 0.0 bar Oil pressure 2 warning delay 0 15 s default : 1 s Oil pressure 2 fault bar default : 0.0 bar Oil pressure 2 fault delay 0 15 s default : 1 s Warning oil temperature C default : 0 C Warning oil temperature 2 delay 0 15 s default : 1 s Malfunction oil temperature C default : 0 C Malfunction oil temperature 2 delay 0 15 s default : 1 s Speed warning rpm default : 0 rpm Speed warning delay 0 15 s default : 1 s 44 AS-002 C EN Translation of the original instructions

92 Malfunction speed rpm default : 0 rpm Malfunction speed delay 0 15 s default : 1 s Warning oil level Lo % default : 0 % Warning oil level Lo delay 0 15 s default : 1 s Malfunction oil level Lo Malfunction oil level Lo delay Warning Oil level Hi % default : 0 % 0 15 s default : 1 s % default : 0 % ENGLISH Warning Oil level Hi delay 0 15 s default : 1 s Malfunction oil level Hi % default : 0 % Malfunction oil level Hi delay 0 15 s default : 1 s Warning pressure rate 1,00 5,00 default : 0,00 Warning pressure rate delay 0 15 s default : 1 s Malfunction pressure rate 1,00 5,00 default : 0,00 Malfunction pressure rate delay 0 15 s default : 1 s Warning vibration 1S % default : 0,00 Warning vibration 1S1 delay 0 15 s default : 1 s Fault vibration 1S % default : 0,00 Fault vibration 1S1 delay 0 15 s default : 1 s Warning vibration 1S % default : 0,00 Warning vibration 1S2 delay 0 15 s default : 1 s Malfunction vibration 1S % default : 0,00 Malfunction vibration 1S2 delay 0 15 s default : 1 s Warning vibration G % default : 0,00 Warning vibration G1 delay 0 15 s default : 1 s Malfunction vibration G % default : 0,00 Malfunction vibration G1 delay 0 15 s default : 1 s AS-002 C EN Translation of the original instructions 45

93 Warning vibration G % default : 0,00 Warning vibration G2 delay 0 15 s default : 1 s Malfunction vibration G % default : 0,00 Malfunction vibration G2 delay 0 15 s default : 1 s ENGLISH Warning vibration 3S1 Warning vibration 3S1 delay Malfunction vibration 3S % default : 0, s default : 1 s % default : 0,00 Malfunction vibration 3S1 delay 0 15 s default : 1 s Warning vibration 3S % default : 0,00 Warning vibration 3S2 delay 0 15 s default : 1 s Malfunction vibration 3S % default : 0,00 Malfunction vibration 3S2 delay 0 15 s default : 1 s 46 AS-002 C EN Translation of the original instructions

94 15.5 Display menu The menu comprises the following submenus: - Limits trend graph - Units - Cleaning display - Screensaver Trend graphs menu Menu path: Main menu Display Limits trend graph All measured values that are displayed on the AERtronic AS 300 can also be graphically displayed over a period of time (trend graph). The upper and lower limits of the trend graphs are set in this menu. ENGLISH Parameter Range of values / basic settings / notes Parameter System pressure graph lower value bar default : 0.00 bar User System pressure graph upper value Discharge pressure (1) graph lower value Discharge pressure (1) graph upper value Graph discharge pressure 2 lower value Graph discharge pressure 2 upper value Oil pressure graph (1) lower value Oil pressure graph (1) upper value Oil pressure graph 2 lower value Oil pressure graph 2 upper value Suction pressure graph lower value Suction pressure graph upper value Graph ambient temp. lower value Graph ambient temp. upper value Graph discharge temperature (1) lower value Graph discharge temperature (1) upper value Graph end temperature 2 lower value Graph end temperature 2 upper value bar default : bar bar default : 0.00 bar bar default : 5.00 bar bar default : 0.00 bar bar default : bar bar default : 0.00 bar bar default : 5.00 bar bar default : 0.00 bar bar default : 5.00 bar bar default : bar bar default : 1.00 bar C default : -50 C C default : 300 C C default : -50 C C default : 300 C C default : -50 C C default : 300 C User User User User User User User User User User User User User User User User User AS-002 C EN Translation of the original instructions 47

95 Graph oil temperature (1) lower value C default : -50 C User Graph oil temperature (1) upper value C default : 300 C User Graph oil temperature 2 lower value C default : -50 C User Graph oil temperature 2 upper value C default : 300 C User ENGLISH Graph intake temperature 2 lower value Graph intake temperature 2 upper value Graph system temperature lower value C default : -50 C C default : 300 C C default : -50 C User User User Graph system temperature upper value C default : 300 C User Rotary speed graph lower value rpm default : 0 rpm User Rotary speed graph upper value % default : 0 % User Vibration graph lower value % default : 100 % User Selected value graph upper value % default : 0 % User Selected value graph lower value % default : 100 % User Oil level graph upper value % default : 0 % User Oil level graph lower value % default : 100 % User Graph pressure rate upper value 1,0 5,0 default : 1,0 User Graph pressure rate lower value 1,0 5,0 default : 5,0 User 48 AS-002 C EN Translation of the original instructions

96 Units menu Menu path: Main menu Display Units Parameter Range of values / basic settings / notes Parameter Pressure unit Temperature unit Bar / PSI default : Bar C / F default : C User User Cleaning display menu Menu path: Main menu Display Cleaning display ENGLISH Screen block for cleaning the display. After pressing this menu item, the following message appears on the screen "Attention: After starting this function the control system can no longer be operated for 1 minute. Pressing the Start button starts the timer, and the display can then be cleaned with a soft cloth Screen saver menu Menu path: Main menu Display Screen saver Parameter Range of values / basic settings / notes Parameter Screensaver Screensaver delay Default brightness Brightness scr. saver Yes / No default : yes 0 99 min default : 5 min If there is no activity on the display in this period, the screen saver is activated % default : 80 % Brightness of the display during use % default : 20 % Brightness of the display when the screen saver is activated. User User User User AS-002 C EN Translation of the original instructions 49

97 15.6 Configuration menu ENGLISH The Configuration menu contains the following submenu: - Function selection - Module selection - Digital inputs - Digital outputs - Analog inputs - Analog outputs.6.1 Menü Funktionsauswahl Menu path: Main menu Configuration Function selection Parameter Range of values / basic settings / notes Parameter Machine type Blower / compr. 1-stage / compr. 2-stage default : Blower The AERtronic AS 300 control system can control both blowers and 1- to 2-stage compressors. This function selection is used to make a basic selection of the modules and the configurable inputs and outputs. Superadmin Motor activation None / Line / Star/Delta default : None - None: The motor activation (star/stop) is not assigned to any digital outputs. This must then be configured under the menu item "Configuration digital outputs". - Net: The motor activation (start/stop) is permanently assigned to the digital output A01- DO1. The parameter "Net" in the "Configuration digital outputs" menu can then no longer be modified. - Star/delta: The activation of system protection is permanently assigned to the digital output A01-DO1. A permanent assignment to the digital outputs on the additional module EM0 is also made. In this context, the output A02-DO1 takes over activation of the star contact and A02-DO2 the activation of the delta contact. The parameters "Net", Star", Delta" can no longer be modified in the "Configuration digital outputs" menu. Superadmin Speed measurement No / yes default : No - No: The speed measurement is deactivated. - Yes: The Namur input on the base module is activated for rotational speed measurement. Superadmin 50 AS-002 C EN Translation of the original instructions

98 Module selection menu Menu path: Main menu Configuration Module selection The installed modules of the control system are assigned in this menu. In principle, 5 different modules can be selected. - EMO = 3 x Digital Input 3 x Digital Output (relay) 1 x Analog Input (4-20mAl) 2 x Analog Input (PT1000, C) - EM1 = 8 x Digital Input 4 x Digital Output (relay) - EM2 = 4 x Digital Output (relay) 2 x Analog Input (PT1000, C) 2 x Analog Input (4-20mA) ENGLISH - EM3 = 4 x Digital Input 2 x Analog Input (PT1000, C) 2 x Analog Input (4-20mA) - EM4 = 4 x Analog Output (4-20mA, 0-5V, 0-10V) - EM5 = Profibus module Attention: The DIP switches located on the side of the module must correspond to the module type addresses. To do this, the first five DIP switches are used. Example: Module EM3 is configured for module type address 5. The DIP switches must be set as follows: Value DIP switch / = 5 on off DIP switch sequence AS-002 C EN Translation of the original instructions 51

99 Parameter Range of values / basic settings / notes Parameter I/O module address 1 Base module default : Module is permanently assigned, change is not User possible I/O module address 2 No module / module EM0 default : no module Superadmin I/O module address 3 No module / module EM1 / module EM2 / module EM3 default : no module Superadmin ENGLISH I/O module address 4 I/O module address 5 I/O module address 6 No module / module EM1 / module EM2 / module EM3 default : no module No module / module EM1 / module EM2 / module EM3 default : no module No module / module EM1 / module EM2 / module EM3 default : no module Superadmin Superadmin Superadmin I/O module address 7 No module / module EM1 / module EM2 / module EM3 default : no module Superadmin I/O module address 8 No module / module EM1 / module EM2 / module EM3 default : no module Superadmin I/O module address 9 No module / module EM1 / module EM2 / module EM3 default : no module Superadmin I/O module address 10 No module / module EM1 / module EM2 / module EM3 default : no module Superadmin I/O module address 11 No module / module EM4 default : no module Superadmin I/O module address 12 No module / module EM4 default : no module Superadmin Module type Profibus No module / Profibus G2 default : no module Superadmin 52 AS-002 C EN Translation of the original instructions

100 Digital inputs menu Menu path: Main menu Configuration Digital inputs Parameter Range of values / basic settings / notes Parameter Base module A01-DI1 (not shown, because permanently reserved for Emergency Stop) A01-DI2 A01-DI3 Module EM0 A02-DI1 A02-DI2 A03-DI3 Module EM1 Possible addresses A03 to A10 DI1 DI2 DI3 DI4 Module EM3 Possible addresses A03 to A10 DI1 DI2 DI3 DI4 - Free: No function selected - Remote On/Off: External start command for starting the machine. This function is only active if the parameter Remote On/Off" in the "Main menu Control system Various" is set to "Digital". With a 1 on this input and the logic function NO, the start command for the main motor would be output at the digital output Net (closed contact). However, the requirement is that the machine signals that it is ready to turn on. (No alarms, no malfunctions, no start block and no blocking due to too many starts/hours may be active). When there is a 0, the start command for the main motor is reset accordingly. - Remote load/idling: When there is load/idling regulation, the machine is switched into operation under load via this digital input. This function is only active if the parameter Remote load/idle" in the "Main menu Control system Various" is set to "Digital". With a 1 on this input and the logic function NO, the machine would switch into operation under load. When there is a 0 there is a switch accordingly into idling mode. - BLC ready: The input is used in BLC=Base Load Change switching and is configured for the slave machine. This input must be associated with the output Malfunction from the master machine. The BLC ready input causes the slave machine to engage without delay when there is a malfunction in the master machine. The function of the input with the logic NO is as follows: - Input "1" No switch-on in BLC - - Input "0" Starting the machine in BLC - Motor current: This input outputs a malfunction message "E003 Main motor overload" and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Fan flow: This input outputs a malfunction message "E005 Fan, and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message Oil mist separator: This input outputs a malfunction message "E006 Separator, and switches off the running machine. ENGLISH AS-002 C EN Translation of the original instructions 53

101 Parameter Range of values / basic settings / notes Parameter ENGLISH In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Oil mist separator 2: This input outputs a malfunction message "E007 Separator 2, and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Oil pump: This input outputs a malfunction message "E008 Oil pump, and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Vibration: This input outputs a malfunction message "E009 Vibration, and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Diagnosis: This input outputs a malfunction message "E010 Machine diagnosis, and switches off the running machine. In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No fault message - Input "0" Fault message - Cooling water flow: This input outputs a warning message "A019 Cooling water flow". In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No warning message - Input "0" Warning message - Steam trap 1: This input outputs a warning message "A020 Condensation drain 1". The activation of the monitoring is delayed for 15 seconds, after which time the machine has switched into Load mode. During a stoppage and in idling mode, the monitoring is suppressed. If the input is configured, but not used, a fixed wire jumper must be installed if necessary (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No warning message - Input "0" Warning message under load Steam trap 2: This input outputs a warning message "A021 Condensation drain 2". The activation of the monitoring is delayed for 15 seconds, after which time the machine has switched into Load mode. During a stoppage and in idling mode, the monitoring is suppressed. 54 AS-002 C EN Translation of the original instructions

102 Parameter Range of values / basic settings / notes Parameter - If the input is configured: - configured, but not used, a fixed wire jumper must be installed if necessary (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No warning message - Input "0" Warning message under load - Aftercooler 1: This input outputs a warning message "A022 Aftercooler 1". In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No warning message - Input "0" Warning message - Aftercooler 2: This input outputs a warning message "A023 Aftercooler 2". In the stopped state, the start readiness is blocked If the input is not being used, a fixed wire jumper must be set in place (see circuit diagram). The function of the input with the logic "NC" is as follows: - Input "1" No warning message - Input "0" Warning message - Priority idle When there is load/idling regulation, the machine is compelled to switch into idling mode via this digital input. This input has priority over the internal load/idling regulation The function when NO logic is used, is as follows: - Input "1" Operation under load possible - Input "0" Idling ENGLISH default : Open Logic of the digital inputs NC / NO default : NC By pressing the button, the logic of the digital inputs are switched. User AS-002 C EN Translation of the original instructions 55

103 Digital outputs menu Menu path: Main menu Configuration Digital outputs The digital outputs are relay contacts and can be loaded with a maximum of 250V AC and 4A. Parameter Range of values / basic settings / notes Parameter ENGLISH Base module A01-DO1 Module EM0 A02-DO1 A02-DO2 A03-DO3 Module EM1 Possible addresses A03 to A10 DO1 DO2 DO3 DO4 Module EM2 Possible addresses A03 to A10 DO1 DO2 DO3 DO4 - Free: No function selected - Motor On: This function of the output is the same as the function of the permanenly assigned output Net. With this relay contact, the main motor must be switched on and off. - Contact closed Main motor start - Contact opened Main motor stop - Load valve: The output switches the machine into operation under load. - - Contact closed Operation under load - - Contact open Idling mode - Oil pump: The output switches an electric oil pump on and off. With the Start/Stop Main Motor, the oil pump is also started and stopped. - - Contact closed Oil pump start - - Contact opened Oil pump stop - Heating: An electrical heater switches on and off as a function of the control parameters Heat switch-on temperature and Heat cut-off temperature. The parameter can be found in the "Main menu" Control system" Regulation". - - Contact closed Heat on - - Contact open Heat off - Maintenance: The output gives information about maintenance to be performed. - - Contact closed Maintenance required - Contact open No maintenance active - Warning: The output gives information about the pending warning. Warnings do not cause a shutdown of a running machine, but block restart when the machine is stopped. - - Contact closed Warning active - Contact open No warning active - Malfunction: The output gives information about the pending malfunction. Malfunctions do not cause a shutdown of a running machine or of the main motor and block restart when the machine is stopped. - - Contact closed Malfunction active - Contact open No malfunction active - Ready: The output gives information about the readiness of the machine to start. The machine is ready to start if no warning is active, no shutdown is active, the restart delay time has expired and no starting block due to too many starts/hours is pending. The machine may only be started if the contact of the Ready output is closed. During operation of the machine, the contact remains closed and opens only after a machine stop (normal cut-off or malfunction active). - - Contact closed Ready to start - Contact open Not ready to start - Operation: The output represents the running message of the machine. - - Contact closed Machine is running - Contact open Machine stoppage - On-load: The solenoid valves of the load/idle regulation are activated with this output. - - Contact closed Operation under load - Contact open Idling mode Remote: The output gives information about the operating location. (Refer to parameter Remote On/Off" in the menu "Main menu" Control system" 56 AS-002 C EN Translation of the original instructions

104 Parameter Range of values / basic settings / notes Parameter - Different ) - - Contact closed Remote - Contact open Place / Panel / Local - Oil separator: Switches an electrical oil mist separator on and off. With main motor start/stop, the oil mist separator is also started and stopped - - Contact closed Oil separator start - Contact opened Oil separator stop - Steam trap 1: Switches an electrical Bekomat drain or condensate separator on and off. The output is activated only in Load mode of the machine. - - Contact closed Separator 1 on - Contact opened Separator 1 off - Steam trap 2: Switches an electrical Bekomat drain or condensate separator on and off. The output is activated only in Load mode of the machine. - - Contact closed Separator 1 on - Contact opened Separator 1 off - Aftercooler: Switches the fan of an electrical aftercooler on and off. With main motor start/stop, also the aftercooler is started and stopped. - - Contact closed Aftercooler start - - Contact opened Aftercooler stop - Steam trap warning: This output issues a warning message if a warning of the steam trap 1 or 2 is active. - - Contact closed Warning active - - Contact open No warning - Aftercooler warning: This output issues a warning message if a warning of the aftercooler is active. - - Contact closed Warning active - - Contact open No warning ENGLISH Comment: For parameterised motor activation type ( Main menu Configuration Function selection ) the first 3 digital outputs are permanently assigned under certain circumstances and cannot be changed. A01-DO1 = Net (with motor control type Net and Star/Delta ) A02-DO1 = "Star" (with motor control type "Star/delta") A02-DO2 = "Delta" (with motor control type "Star/delta") default : Open AS-002 C EN Translation of the original instructions 57

105 ENGLISH Analogue inputs menu Menu path: Main menu Configuration Analogue inputs Parameter Range of values / basic settings / notes Parameter Free / oil level default : Open - Free: No oil level measurement. - Oil level: Activates the oil level measurement. Base module A01-AI1 Base module A01-AI2 A01-AI3 Module EM0 A02-AI1 Module EM2 Possible addresses A03 to A10 AI1 AI2 Module EM3 Possible addresses A03 to A10 AI1 AI2 - min: % / Limit for the lower value at 0.5V - max: % / Limit for the highest value at 4.5V - Free: No measurement active. - Std intake pressure: Measuring range bar standard intake pressure measurement. - VD intake pressure: Measuring range bar compressor intake pressure measurement - VDV intake pressure: : Measuring range bar compressor intake pressure measurement with admission pressure - Discharge pressure std: Measuring range depends on machine type ("Main menu" "Configuration" "Function selection"): Blower = bar "Compr. 1 stage = bar "Compr. 2 stage = bar - Discharge VDV: Measuring range bar compressor discharge pressure measurement with admission pressure. - Oil pressure: Measuring range bar - System pressure: Measuring range depends on machine type ("Main menu" "Configuration" "Function selection"): Blower = bar "Compr. 1 stage = bar "Compr. 2 stage = bar - External set value: An external speed preset can be made at this analog output. In so doing, the parameter Speed set point must be set to External. The parameter can be found in the "Main menu" Control system" Regulation". If this function is selected, the speed is read in at the input and output again at the Pressure regulation output. Comment: During a stoppage and in idling mode, the monitoring outputs basically 4mA (minimum speed) an external pre-set is not possible in this case. - Oil pressure 2: Measuring range bar oil pressure measurement of the 2nd stage - Discharge pressure 2: Measuring range bar discharge pressure measurement of the 2nd stage - Vibration 1S1: Measuring range % Vibration measurement 1 of the 1st stage - Vibration 1S2: Measuring range % Vibration measurement 1 of the 1st stage - Vibration G1: Measuring range % Vibration measurement 1 of the 1st stage - Vibration G2: Measuring range % Vibration measurement 2 of the 1st stage - Vibration 3S1: Measuring range % Vibration measurement 3 of the 1st stage - Vibration 3S2: Measuring range % Vibration measurement 1 of the 1st stage default : Open 58 AS-002 C EN Translation of the original instructions

106 Module EM0 A02-AI2 A02-AI3 Module EM2 Possible addresses A03 to A10 AI3 AI4 Module EM3 Possible addresses A03 to A10 AI3 AI4 - Free: No measurement active. - Ambient temperature: Measuring range C. The sound enclosure heat, for example, is switched on and off as a function of this temperature. - Oil temperature 1: Measuring range C oil temperature of the 1st stage - Discharge temperature 1: Measuring range C discharge temperature of the 1st stage - Intake temperature 2: Measuring range C intake temperature of the 2nd stage - Oil temperature 2: Measuring range C oil temperature of the 1st stage - Discharge temperature 2: Measuring range C discharge temperature of the 1st stage - System temperature: Measuring range C temperature measurement at the output of the machine Superadmin ENGLISH default : Open Analogue outputs menu Menu path: Main menu Configuration Analogue outputs Parameter Range of values / basic settings / notes Parameter - Free: No output is activated. - Intake pressure: Outputs the current value of the intake pressure. The measuring range is the same as that which was configured under the analog Intake pressure inputs. - Discharge pressure: Outputs the current value of the discharge pressure. The measuring range is the same as that which was configured under the analog Discharge pressure inputs. - System pressure: Outputs the current value of the discharge pressure. The measuring range is the same as that which was configured under the analog System pressure inputs. - Oil pressure: Outputs the current value of the oil Module EM4 pressure. The measuring range is bar A10-AO1 - Vibration: Outputs the current value of the A10-AO2 vibration. The measuring range is %. A11-AO1 A11-AO2 - Discharge temperature: Outputs the current discharge temperature. The measuring range is C - Oil temperature: Outputs the current discharge temperature. The measuring range is C - Pressure regulation:emits the manipulated variable of the PID controller %. This is generally the speed preset for a frequency converter and is between the minimum and maximum speed. This results in 0 % min. speed and 100 % max. speed. When the machine is stopped and also during idling mode, 0 % is always output. (see also menu item PID controller) default : Open AS-002 C EN Translation of the original instructions 59

107 16. Connection of the control system 16. Connection of the supply voltage Connection example with a AC V 50/ 60Hz power supply. ENGLISH Connection example with a AC V 50/ 60Hz power supply. Comment: The two connections that are indicated are to be seen as an example. The exact connection of the supply voltage can be taken from the respective circuit diagram. 60 AS-002 C EN Translation of the original instructions

108 16.2 Connection example for the digital inputs A42: A01-DI1 EMERGENCY STOP permanently assigned input for the connection of an EMERGENCY STOP device supplied by the customer. If this input is not used, a wire jumper should be installed from X3.1 to X3.2, because otherwise the fault message E002 Emergency Stop is active. Note: The input does not correspond to the EMERGENCY STOP function according to DIN EN A42: A01-DI2 Input for motor protection device of the main motor, 0-signal triggers a cut-off or malfunction. If this input is not used, a wire jumper should be installed from X3.1 to X3.3, because otherwise the fault message E003 Main motor overload is active. A42: A01-DI3 Remote start / stop of the rotary piston machine, 1-Signal = Start, 0-Signal = Stop. Comment: If the machine fails due to a malfunction, the start signal must be set to 0. If all faults are cleared and the machine is ready to start again, it is possible to restart via this digital input. This prevents an inadvertent starting of the machine after a malfunction is acknowledged. ENGLISH Attention: The illustration is only one wiring example. The exact wiring can be seen in the respective circuit diagram. The exact descriptions of the digital inputs are given in the chapter (Parameters Configuration Digital inputs). AS-002 C EN Translation of the original instructions 61

109 16.3 Connection example for the digital outputs ENGLISH A42: A01-DO1 Line protection, with the closed contact at this relay output, the main motor absolutely must be started. If the contact is open, the main motor absolutely must be stopped or switched off. A45: A02-DO1 Collective fault message, contact closed if there is no malfunction. Contact open with pending malfunction also results in an open Line protection contact. The main motor is switched off. A45: A02-DO2 Collective warning message, contact closed if there is no malfunction. Contact open with a warning pending has no effect on the Line protection output while the machine is running but prevents the restart when stopped. A45: A02-DO3 Message of readiness for operation, contact closed if there is no warning / no malfunction / no starting block. With the closed contact, the machine is ready to start. Important: The contact also remains closed when the machine is running and opens only when there is a malfunction or a stop command. Attention: The illustration is only one wiring example. The exact wiring can be seen in the respective circuit diagram. The exact descriptions of the digital outputs are given in the chapter (Parameters Configuration Digital outputs). 62 AS-002 C EN Translation of the original instructions

110 16.4 Connection example for activating a frequency converter A47: A04-AI1 System pressure, actual value for PID controller. If the controller is activated (refer to menu Regulation with PID controller), an attempt is made using the analog output Set value frequency converter to keep the system pressure equal to the set pressure. Example: If the system pressure falls below the set pressure, the speed preset is increased If the system pressure increases above the set pressure, the speed preset is reduced A47: A04-AI2 If the speed preset is not to be made via the internal PID controller, they can also be externally predetermined. In so doing the parameter Speed set point" must be set in the menu (Main menu Control system Regulation) to external. Then the speed preset is carried out by the AERtronic and at this analog input and output again at the A011-A01 output. Attention: A speed preset is not possible in idling mode and with the machine turned off. ENGLISH A51: A011-AO1 Frequency converter set value, the speed for the frequency converter is preset here. The output signal 4mA 20mA presets the minimum maximum speed in the range. This means a mandatorily required limitation of the minimum and maximum speed in the frequency converter. Operation outside of these speeds would result in damage to the machine. Attention: In idling mode and with the machine switched off, 4mA (0%) is output. The analog output emits the correct signal only after the engine is started and up to speed. AS-002 C EN Translation of the original instructions 63

111 ENGLISH Attention: The illustration is only one wiring example. The exact wiring can be seen in the respective circuit diagram. The exact descriptions of the analog inputs and outputs are given in the chapter (Parameter Configuration Analog inputs / analog outputs). Exact descriptions of the digital outputs are given in the chapter (Parameters Control system Regulation). Additional explanations about the PID controller are in the corresponding menu item. 64 AS-002 C EN Translation of the original instructions

112 17. Fault / malfunction messages If a new malfunction message is present, the screen background in the display is red and flashing. If the message was acknowledged, the display stops flashing but remains continuously red until the cause of the error has been eliminated. The assembly is switched off immediately. The message number of a malfunction message always starts with E. Error Codes Designation Note ENGLISH E001 Power outage Power outage, message appears after the voltage is restored E002 Emergency OFF EMERGENCY OFF was pressed E003 Main motor overload E004 Main motor excess temperature E005 Fan E006 Separator E007 Separator 2 E008 Oil pump E009 Vibration: E010 Machine diagnostics E011 E016 The corresponding digital input has triggered. Reserved E017 Suction pressure Measured value < limit value LL E018 Pressure rate Calculated value > Limit value HH E019 Discharge pressure Measured value < limit value HH E020 Discharge temperature Measured value < limit value HH E021 System temperature Measured value < limit value HH E022 Oil pressure Measured value < limit value LL E023 Oil temperature Measured value < limit value HH E024 Suction temperature 2 Measured value < limit value HH E025 Discharge pressure 2 Measured value < limit value HH E026 Discharge temperature 2 Measured value < limit value HH E027 Oil pressure 2 Measured value < limit value LL E028 Oil temperature 2 Measured value < limit value HH E029 E030 Speed Measured value < limit value LL E031 Oil level Lo Measured value < limit value LL E032 Oil level Hi Measured value < limit value HH AS-002 C EN Translation of the original instructions 65

113 Error Codes Designation Note ENGLISH E033 Intake pressure sensor E034 Ambient temperature sensor E035 Discharge pressure sensor E036 Discharge temperature sensor E037 System pressure sensor E038 System temperature 2 sensor E039 Oil pressure sensor E040 Oil temperature sensor E041 Intake temperature 2 sensor E042 Discharge pressure sensor 2 E043 Discharge temperature sensor 2 E044 Oil pressure sensor 2 E045 Oil temperature sensor 2 E046 Speed sensor E047 E048 External set value E049 Oil level sensor E050 E051 E052 Sensor or senor line malfunction E053 Vibration 1S1 Measured value < limit value HH E054 Vibration G1 Measured value < limit value HH E055 Vibration 3S1 Measured value < limit value HH E056 Vibration 1S2 Measured value < limit value HH E057 Vibration G2 Measured value < limit value HH E058 Vibration 3S2 Measured value < limit value HH E059 Sensor vibration 1S1 E060 Vibration sensor G1 E061 Sensor vibration 3S1 Sensor or senor line malfunction E062 Sensor vibration 1S2 E063 Vibration sensor G2 E064 Sensor vibration 3S2 E065 E080 Reserved 66 AS-002 C EN Translation of the original instructions

114 Error Codes Designation Note E081 I/O module address 1 E082 I/O module address 2 E083 I/O module address 3 E084 I/O module address 4 E085 I/O module address 5 E086 I/O module address 6 E087 I/O module address 7 E088 I/O module address 8 E089 I/O module address 9 E090 I/O module address 10 Module or communication with the module disrupted. ENGLISH E091 I/O module address 11 Analog output E092 I/O module address 12 Analog output E093 E094 I/O module address 14 E095 I/O module address 15 E096 Parameter incorrect AS-002 C EN Translation of the original instructions 67

115 18. Alarm / warning messages If a new alarm message is present, the screen background in the display is yellow and flashing. If the message was acknowledged, the display stops flashing but continues to remain yellow until the cause of the alarm message has been eliminated. The assembly is not switched off. The message number of an alarm message always starts with E. ENGLISH Alarm- Codes A001 Designation Note A002 Suction pressure Measured value < limit value L A003 Min. ambient temperature Measured value < limit value L A004 Max. ambient temperature Measured value < limit value H A005 Discharge pressure Measured value < limit value H A006 Discharge temperature Measured value < limit value H A007 System temperature Measured value < limit value H A008 Oil pressure Measured value < limit value L A009 Oil temperature Measured value < limit value H A010 Suction temperature 2 Measured value < limit value H A011 Discharge pressure 2 Measured value < limit value H A012 Discharge temperature 2 Measured value < limit value H A013 Oil pressure 2 Measured value < limit value L A014 Oil temperature 2 Measured value < limit value H A015 Speed Measured value < limit value L A016 Oil level Lo Measured value < limit value L A017 Oil level Hi Measured value < Limit value H A018 Pressure rate Calculated value > Limit value H A019 Cooling water flow Digital input A020 Condensate drain 1 Digital input A021 Condensate drain 2 Digital input A022 Aftercooler 1 Digital input A023 Aftercooler 2 Digital input A024 A025 Vibration 1S1 Measured value < limit value H A026 Vibration G1 Measured value < limit value H A027 Vibration 3S1 Measured value < limit value H A028 Vibration 1S2 Measured value < limit value H A029 Vibration G2 Measured value < limit value H A030 Vibration 3S2 Measured value < limit value H A031 A47 Reserved A048 I/O module address 13 Profibus DP module fault 68 AS-002 C EN Translation of the original instructions

116 19. Maintenance message If a new maintenance message is displayed, the screen background is yellow and flashing. If the message in the INFO area has been acknowledged, then the display stops flashing. However, the screen background remains yellow until the service counter of the maintenance message in the service menu has been reset to the starting value. This operation can be carried out with the user password The message number of a maintenance message always begins with W. Alarm- Codes Designation Note ENGLISH W001 W002 W003 W004 W005 W006 W007 W008 W009 W010 W011 W012 W013 W014 W015 W016 Intake filter maintenance interval Pressure maintenance interval. Filter element V-belt maintenance interval Coupling maintenance interval Pressure valve maintenance interval Lubricating oil maintenance interval Oil filter maintenance interval Check valve maintenance interval Oil separator Maintenance interval Water cooling Maintenance interval Steam trap Maintenance interval 1st maintenance Main inspection maintenence interval Battery The time until the next maintenance is less than 100h. Carry out maintenance and reset maintenance counter. ADMIN access authorization required AS-002 C EN Translation of the original instructions 69

117 20. Status messages The messages are displayed in the INFO area. The button with the i flashes during the duration of the display. The message number of a status message always begins with M. ENGLISH Alarm codes Designation Note M01 Start temperature too low Ambient temperature is < than the limit value / no starting of the machine possible M02 Switching cycles exceeded Too many engine starts in an hour M03 Restart delay active Active after the machine is cut out M04 Maintenance on timer Only active when timer function is switched on M05 Automatic restart Only active during a mains failure and with function switched on M06 M016 Reserved 70 AS-002 C EN Translation of the original instructions

118 21. Connection of the Modbus X99: Standard connection for the Modbus RTU ENGLISH The standard RS485 interface is accessible on the plug -X99 (Mini Combicon MC1,5/4-ST-3,81, Fabrikat Phoenix Contact; AM-Sno ).. The AERtronic AS 300 can be connected via this interface and a converter USB/ RS-485 directly to a PC. A direct connection to a Modbus master system can also be realized with this interface. A Modbus address list is accessible. Parameter Range of values / basic setting / notes Parameter Address 0-31 default: 1 USER Record Standard / MODBUS default: Standard USER Baud rate 4800 / 9600 / / / default: USER Communication menu Please deactivate the Profibus module in the configuration. Although it is possible to simultaneously read data via Profibus and Modbus, in this case control via Modbus is not possible. The background for this is that data are always exchanged between the Profibus module and the AERtronic, even without Profibus master. In this case, the AERtronic recognizes that the Profibus Master is missing and switches over to on-site operation. Via Modbus there is then a switch back to remote operation, via Profibus to on-site, etc.... You see this then as a short appearance of the lock. AS-002 C EN Translation of the original instructions 71

119 22. Connection of the Profibus Function The Profibus-DP module makes it possible to connect an AERtronic AS 300 control as a slave to the Profibus-DP according to EN The control system affixed to the module via the MK200 system bus and queried by the module via the appropriate protocol. ENGLISH PROFIBUS-DP transmission technology RS 485, 9.6 kbit/s to 1.5 mbit/s electrically isolated from the microcontroller Connection via 9-pin MinD-socket PROFIBUS-DP Slave protocol processing via Siemens ASIC SPC3 and integrated Microcontroller 2 hexadecimal switch for the Profibus address setting 4 LEDs for the communication display Connection of teh Profibus DP Optimum connection fot the Profibus DP. The bus address is to be set directly on the module. Connection of the AERtronic AS 300 to the Profibus DP Address setting: In this case the Profibus address of the module is set as a hexadecimal number, (00 to FF hexadecimal corresponds to 0 to 255 decimal). left rotary switch : Superior Address (x16), right rotary switch : Inferior Address (x1) The address FF is reserved for the firmware update. Note: Only when the power supply is switched on is a revised address read in! 72 AS-002 C EN Translation of the original instructions

120 23. Battery change A battery change is to be carried out without password entry. The machine is not switched off by the Battery warning message while it is running. The limit values saved in the AERtronic AS 300 and settings are not changed. Messages ENGLISH Fault registry menu W16 Battery E082 I/O Module Address 2 A004 Max. ambient temperature A008 Oil pressure The following procedure has to be kept to when changing the battery: 1. Take machine out of service, switch off power supply. 2. Remove AERtronic AS 300, observe the figures below to do this. 3. Remove housing rear wall with a screwdriver. 4. Pry out battery bracket. 5. Remove spent battery and dispose of it properly. 6. Install new battery. 7. Use battery bracket. 8. Attach housing rear wall with screwdriver. 9. Install AERtronic AS 300 in the front of the unit. 10. Switch on power supply. 11. Acknowledge Battery malfunction message 12. Switch of power supply. 13. Switch on power supply. 14. The control system is ready again for operation. AS-002 C EN Translation of the original instructions 73

121 ENGLISH 74 AS-002 C EN Translation of the original instructions

122 24. Technical data Relay outputs The current carrying capacity 4 A relates to ohmic load Analog outputs Output range : ma / V Resolution : 2 10 Maximum voltage : 10 V potential-free, but with common signal ground for both outputs ENGLISH During use as current output : Load < 500 ohms During use as voltage output : Load > 100 kohm Digital inputs Nominal voltage : 24 V DC Maximum voltage : 30 V DC Power consumption : ma at 24 V Activation threshold : approx. 13 V or 8 V with PTC input Cut-off threshold : approx. 9 V or 6 V with PTC input max. frequency : approx. 0.5 Hz Ambient conditions Operating temperature : C Storage temperature : C rel. humidity : max. 90 %, non-condensing AS-002 C EN Translation of the original instructions 75

123 ENGLISH 76 AS-002 C EN Translation of the original instructions

124 Information sheet Info - bladzijde 25. INFO - PAGE Page infos PaginaInformativa ENGLISH Gegenüber Darstellungen und Angaben dieser Betriebsanleitung sind technische Änderungen, die zur Verbesserung der Drehkolbenmaschinen notwendig werden, vorbehalten. This operating- and installation manual is subject to engineering changes necessary for the compressor advancement. Nous nous réservons le droit dans les instructions de service procéder à toutes modifications techniques utiles visant à améliorer la qualité des compresseurs. Wat de betrft de tekeningen en gegevens in deze bedienings- en opstellings-hanleiding verbetering van de schroefcompressor noodzakelijk worden, voorbehouden. Nos reservamos el derecho de efectuar, frente a las representaciones e indicaciones de esta instrucciones de montage servicio modificaciones técnicas necesarias para perfeccionar. Rispetto all'illustrazione ed alle indicazioni di questa Istruzioni di Esercizio ci si riserva quelle modifiche tecniche che sono necessarie per migliorare i compressori. AS-002 C EN Translation of the original instructions 77

125 ENGLISH Aerzener Maschinenfabrik GmbH Reherweg Aerzen Postfach Aerzen Telefax / info@aerzener.de Customer service / Aerzener International Rental B.V. phone +31 (0) Telefax +31 (0) info@airental.nl Aerzen on the Internet 78 AS-002 C EN Translation of the original instructions

126 AERZEN USA CORPORATION 108 Independence Way Coatesville, Pa Phone: Fax: Nominal Voltage Control Voltage Measuring Signal Rating Degree of Protection Machine Type 3/PE~ 480 V 60 Hz 24 VDC DIN-EN IP 54 Delta Hybrid Electrical- Documentation: Order No. Customer Information - - Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

127 TABLE OF CONTENTS Sheet Description Additional Description 1 Circuit Diagram Cover Sheet 2 Table of Contents 3 Circuit Diagram Layout Diagram 4 Circuit Diagram Power Supply & Controller 5 Circuit Diagram Modbus & Emergency Stop 6 Circuit Diagram Digital Outputs 7 Circuit Diagram Digital Inputs 8 Circuit Diagram Analog Inputs & Analog Outputs 9 Circuit Diagram Oil Demister 10 Circuit Diagram Analog Inputs & Analog Outputs Circuit Diagram List of Components Fan for Sound Enclosure Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

128 -6B4A -2K3B -2K4B -2K5B -6B5A Basis Modul EM 0 EM 2-6B7A -1T4B -10Q5D -X7 -X1 -X2 -X3 -X4 -X9 -X dimension: W= 539mm [21.2"] H = 500mm [19.7"] D = 220mm [8.7"] color = same as the sound enclosure Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

129 -L+ /5.0 -M /5.0 -PE -PA1 /5.0 Aerzener controler CPU/ Touch-Display 120mA SUB D -2K2B M6-2K3B YE 5/M1 4/M2 3/M3 1/M4 2/M5 6/GN 7/BU 8/VT 9/GY S OG M7 M8 RD BK BN GN BU VT -2W2D x0,34mm² -1T4B 10A -X VDC = ~ VAC L1 L2 DI1 DI2 DI3 PTC DI4 /7.1 DI5 NAMUR M9 M10 /7.1 /7.2 /7.3 M1 M2 DO1 /6.1 AI1 AI2 AI3 M3 M4 Base-Modul 5DI / 1DO / 3AI Adr.: 1 M5 /8.2 /8.4 M11 M12 M13 M14 M15 200mA M1 M2 M3 M4 M5-2K4B DI1 DI2 DI3 /7.4 /7.5 /11.6 DO1 DO2 DO3 /6.2 /6.3 /6.4 AI1 AI2 AI3 EM 0 3DI / 3DO / 3AI Adr.: 2 /8.5 /8.7 /8.8 M11 M12 M13 M14 M15 150mA L1 L2 L3 2 L PE BU BU WH -WT40 H05V-K 3X1,0mm² -1L+24V2 /9.0 -X9:1 -GND /9.0 -X9:2 -RS485.GND /5.0 -RS485.B(-) /5.0 -RS485.A(+) /5.0-1W1D H07V-K 6X1,5mm² BK BK BK PE PE BU -1L1 / Q5D:1-1L2 / Q5D:3-1L3 / Q5D:5 M1 M2 M3 M4 M5-2K5B Analogeingabe analog input A04- AI1 AI2 AI3 AI4 Digitalausgänge M11 DO1 DO2 DO3 DO4 EM 2 4AI / 4RO Adr.: 4 digital inputs digital outputs analog input A01- A01- A01- digital inputs digital outputs analog input A02- A02- A02- digital outputs A04- /6.5 /9.4 /11.7 /6.6 M12 M13 M14 M15 200mA AM Customer customer Power supply 3/PE 460VAC; LS 10A(B,C) multi wire; Amax= 2,5mm² single wire; Amax= 4,0mm² switching operation with power electrical equipment on/ off Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

130 -L+ /4.9 -M /4.9 -PA1 /4.9 -L+ /7.0 -M /11.3 -PA1 /7.0 emergency stop -3S7B PE -3W7D Oelflex C100 5G 0,75mm² -RS485.GND /4.9 -RS485.B(-) /4.9 -RS485.A(+) /4.9 WH 5 6-2K3B:14 /7.0 -X3:3 /7.0-2K3B:25 /6.0 -X2:1 /6.0-2W2D H05V-K 4X0,75mm² Modbus- Interface RS 485 1= GND (VT) 2= B(-)(BU) 3= A(+)(GN) 4=S customer AM Customer -X X wired to main contactor (A01-DO1) wired to emergency stop (A01-DI1) open Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

131 1 The use of the "main contactor" output is mandatory!!! Contact Ratings on Relays VAC 2 30 VDC main contactor frequency inverter fault alarm/ warning ready to run remote -2K3B /4.2 A01-DO1-2K4B /4.4 A02-DO1-2K4B /4.4 A02-DO2-2K4B /4.4 A02-DO3-2K5B /4.7 A04-DO1 OG OG OG OG OG OG OG OG OG OG /5.9 /5.9 -X7:4 -X7:1 -X AM W2E customer main contactor / frequency inverter general fault alarm / warning ready to run CUSTOMER remote H05V-K 10X1,0mm² Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

132 Thermistor- Motorschutz thermistor motor protection -R71 PTC - + Θ /5.6 -PA1 -PA1 /8.0-2K3B 3 4-2K3B /4.2 A01-DI5 A01-DI6 thermistor motor protection not used -2K3B /4.2 emergency stop A01-DI1-2K3B /4.2 motor protection main drive A01-DI2-2K3B /4.2 remote on/ off A01-DI3-2K4B /4.4 not used A02-DI1-2K4B /4.4 not used A02-DI W2B Oelflex-115CY 2x0,75mm² /5.9 -X7: /5.9 -X7:2 /4.9 -M -M /9.3 /5.6 -L+ -L+ /11.3 BU BU BU BU BU -X AM customer 7 8-5W2E H05V-K 5X1,0mm² customer emergency stop main drive motor protection remote _ on / off not used not used Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

133 -PA1 /7.9 -PA1 +17V M /4.4 A/IN A01-AI2-2K3B +-1.0Bar P I B4A +17V M /4.4 A/IN A01-AI3-2K3B bar P I B5A + M /4.7 A02-AI2-2K4B θ - + discharge -7B2A PT M /4.7 A02-AI3-2K4B AM Customer 1-7W2B TeCSI 2x0,25mm² 2 GY GY +17V M V/IN A01-AI1-2K3B BU -6W4B H05V-K 2X1,0mm² BU -6W5B H05K-V 2X1,0mm² θ B4A PT W4B TeCSI 2X0,25mm² 2 customer temperature oil temperature discharge pressure inlet pressure discharge temperature oil temperature discharge pressure inlet pressure not used +17V M /4.7 A/IN A02-AI1-2K4B bar P I B7A GY BU -6W7B H05K-V 2X1,0mm² oil pressure oil pressure D36S/H D46L D62S/H D75L D98S/H YES YES NO NO YES HYBRID MODEL MONITORS OIL PRESSURE D36S/H D46L D62S/H D75L D98S/H YES YES NO NO YES HYBRID MODEL MONITORS OIL TEMP. -PA1 /10.0 Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

134 Oil Mist Separator -9M2A 75W 24VDC M = K3B /4.2 Diagnostic A01-DI4-2K5B /4.7 Oil Mist Seperator A04-DO /4.2 /4.2 -L+24V2 -GND AM customer customer RD BK2 PK BK4 20-9W2B 4X1,5mm² -X9 10A k3 0k Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

135 AM customer customer Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

136 fan part no. type U/ f I power flow rate normal size wire jumper -10M2A fan for acoustic hood M 3~ PE -SM112 θ T1 UL Standard A4D315AP0313 A4400-AM06-03 A4D450-AO10-04 A4D500-AD01-05 [V] / [Hz] 460 / / / / 60 [A] 0,27 0,67 1,15 1,86 [kw] 0,13 0,31 0,53 0,86 [m3/hr] DN100/125 DN150 DN200 DN250/300 -X4: X4: X4; none -X4; none TOP T2 -X4-10Q5D 8 AM customer customer PE 1 2 U V W -10W2B H07RN-F 4G1,5mm² W3B Oelflex-150Q 2X0,75mm² -10Q5D fan for acoustic hood fault -2K4B /4.4 A02-DI3-2K4B fan for acoustic hood /4.7 A04-DO /7.9 -L L+ fan for acoustic hood -1L1 /4.2 -X1:1-1L2 /4.2 -X1:2-10Q5D R M L Us MAN RES E AUT -1L3 /4.2 -X1:3 /5.6 -M -M Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

137 LIST OF COMPONENTS Item Component Sheet Description Manufacturer Manufactures Item Number Manufactures Model / Type Aerzen Item Number 1-2K2B 4 BASIS MODULE RSI ELECTOTECHNIK AM2 Control K3B 4 Touch Display (CPU/HMI) RSI ELECTOTECHNIK TAN GR4.3 TFT K4B 4 EM0 MODULE RSI ELECTOTECHNIK AM2EM K5B 4 EM2 MODULE RSI ELECTOTECHNIK AM2EM B4A 8 Pressure Transmitter ( bar) HUBA Control AG W DT B5A 8 Pressure Transmitter ( bar) HUBA Control AG W DT B7A 8 Pressure Transmitter ( bar) HUBA Control AG W DT B2A 8 Temperature Sensor ( C) ELECTROTHERM PT1000, 160mm B4A 8 Temperature Sensor ( C) ELECTROTHERM PT1000, 60mm Q5D 11 Contactor Phoenix Contact ELR W3-24DC/500AC T4B 4 Power Supply BLOCK Transformatoren PVSE400/24-10 PVSE400/ S7B 5 E-Stop Button MOELLER - M22-PV/(3)CK S7B 5 E-Stop Protective Collar MOELLER M22-XGPV S7B 5 E-Stop Shroud MOELLER M22-H S7BA 5 E-Stop Mounting Plate MOELLER M22-XE X1 4 Terminal Block Phoenix Contact PITS2.5-Twin X2 6 Terminal Block Phoenix Contact PITS2.5-Twin X3 7 Terminal Block Phoenix Contact PITS2.5-Twin X4 11 Terminal Block Phoenix Contact PITS2.5-Twin X9 5 Terminal Block Phoenix Contact PITS2.5-Twin X9 5 Fuse (10A) Farnell X9 5 Resistor (0.820kΩ) Conrad X9 5 Resistor (3.3kΩ) Conrad X11 5 Terminal Block Phoenix Contact PITS2.5-Twin Aerzener Maschinenfabrik GmbH Aerzen-GERMANY Aerzen

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139 Technical overview f'ressure ran e Kelat1ve Absolute o crat1n cond111ons Medium 1 empera ture Tolerable overload Kepture pressure Materials case Materials In contact with the medium Medium I ambient Stora e Sensor Pressu re connection Sealing material u - 60 bar u... L.5-16 bar liquids and gases -ls C U C 2 x fs (max. 80 bar) 3 x fs (max. 9U bar) PA6 Ceramic Al20 1 (96%) Stainless steel 1.4:l0 ~ I AISI 303 FPM, Et'DM, NBR, MVQ Llectncal overview Output Power supply Load Current consumption'' L wire 4... LUmA 4... LUmA 8.U... :l3 VDC 10.U... :l:l VDC < ~~~ [Ohm) < liim1l,~ [OhmJ <LO ma < 20 ma u... 5 v 9.U VDC: > lo kohm/< luun~ < 5mA 3wire V VDC > 10 kohm I < luu. nl < 5 ma U... luv :l:l VDC > lu kohm/ < 100 nl < b ma rat1om ~U% 5 VDC ±5% > 10 kohm I< 100 nf < 3 ma Polarity reversal protection Short orcu1t proof and protected against polarity reversal. Each connection 1s protected against crossover up to max. supply voltage. 1.Jvnam1c res onse Res onse time Load c cle < 5 ms < 50 HZ t'rotcrnon standard IP 65 Llectncal connection Cable l.~ m Connector DIN EN 175.:JO A Connector DIN EN 1 753U1 8U:l-C (mini DIN) Connector M llxl f'ressurc connection Inside thread Outside thread G ;. m1t O Rmg sealing '!. -18 NPT G v., sealed at back, DIN 385L form lo RY.. DIN 299~ G Y., sealed at back and manometer (comb1) G \':, sealed at back and manometer (comb1) 1nstalla11on arrangement Kecommened: Pressure connection downwards I ests / Admissions Electromagnetic compatibility Wei hi With inside thread w ith ous1de thread With cable 1.5 m add1t1onal CE conformity acc. EN b 1 :JLb 2 :l g - 40 g Packaging (t'leasc state on order) single packaging in cardboard Multiple packaging 1n cardboard per 25 pcs. Accuracy Parameter I olerance zero point Tolerance full scale Resolution lotal o(lineanty, hysteresis and repeatability Long term stability acc. to IJIN EN c zero point 2 1 I c sens1t1v1ty 2 1 I c sens1t1v1tv 21 Test conditions: un11e % ts max. max., % Is J ofs max. % fs... % ts max. % fs/l OK typ. % fs/1 OK max. % fsll OK 25 c, 45% RH, power supply 24 voe TC z.p. I TC s C ± 1.0 ± 1.U 0. 1 ±0.5 ± 1.0 ±

140 W CUSTOM -1.0 to +1.0 bar

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143 I Technical overview Pressure ran e Relative Abs~ 0 eratin conditions Medium Temperature Tolerable overload Repture pressure bar bar Liquids and gases Medium I ambient c Stora e so c 2 x Is (max. 80 bar) 3 x Is (max. 90 bar) Materials Case PA6 Sensor Ceramic Al,01 (96%) Materials in contact with the medium Pressure connection Stainless steel / AISI 303 Sealing material FPM, EPDM, NBR. MVQ Electrical overview Output Power supply Load Current consumption ma VDC < '"""'tiilf',tt!"hv[ohm] < 20 ma 2 wire ma VDC < ''""'W't '"v!ohml < 20 ma o... 5 v voe > 10 kohm I< 100 nf < 5 ma V VDC > 10 kohm I< 100 nf < 5 ma 3 wire V VDC > 10kOhm/<100 nf < 6 ma ratiom % 5 VDC :1:5% > 10 kohm I< 100 nf < 3 ma Polarity reversal protection Short circuit proof and protected against polarity reversal. Each connection is protected against crossover up to max. supply voltage. D namic res onse Res onse time Load cle < 5ms < 50 Hz Protection standard IP 65 Electrical connection Cable 1.5 m Connector DIN EN A Connector DIN EN C (mini DIN) Connector M12x1 Pressure connection Inside thread Outside thread G Y. mit 0 -Ring sealing V.. -18NPT G V.. sealed at back DIN 3852 form E RV.. DIN 2999 G V., sealed at back and manometer (combq G \4, sealed at back and manometer (combi) lnstallat1on arrangement Recommened: Pressure connection downwards Tests I Admissions (Jectromagnetic compatibility Wet ht With inside thread With ouside thread With cable 1.5 m additional ((conformity acc. EN J g - 40 g Packaging (Please state on order) Single packaging in cardboard Accuracy Parameter Unite Tolerance zero ooint max. % fs Tolerance full scale max. %Is Resolution % Is Total of linearity, hvsteresis and reoeatabilitv max. % fs Lona term stabilitv acc. to DIN EN % fs TC zero ooint 2) max. % fs/lok TC sensitivitv 1l tvo. % fs/lok TC sensitivitv 21 max. % fs/lok Test conditions: 25 C, 45% RH, power supply 24 VDC TC z.p. I TC s C :I: 1.0 :I: :1:0.5 :I: 1.0 :1: I 11 At nominal pressure " TC = Temperature coefficient 2/5 Huba Control type Technical data subject to change - Edition

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146 Thermocouples Cable sensors Series K5T Application temperature on inquiry, dependent on sensor and protective tube material Thermo junction J (Fe-CuNi) DIN EN K (NiCr-Ni) DIN EN on inquiry Number of Thermo junction 1 thermocouple 2 thermocouples Measuring point design insulated of protective tube connected to protective tube disconnected bead at 2 thermocouples connected bead at 2 thermocouples Protective tube material on inquiry Protective tube diameter d on inquiry mm Insert length L 1 on inquiry min. length of thread mm Type of connection cable on inquiry Cable length L 2 on inquiry min. 100 mm Bend protection without with spiral spring Thread M10 G1/4A G1/2A on inquiry Issue of 10/2013 Subject to change without notice electrotherm Gesellschaft für Sensorik und thermische Meßtechnik mbh Gewerbepark 6, D Geraberg Tel.: Fax: (0) (0) info@electrotherm.de

147 Thermocouples Cable sensors Series K5T Connector free ends connector on inquiry declare desired temperature range for case of application Issue of 10/2013 Subject to change without notice electrotherm Gesellschaft für Sensorik und thermische Meßtechnik mbh Gewerbepark 6, D Geraberg Tel.: Fax: (0) (0) info@electrotherm.de

148 Thermocouples Cable sensors Series K5T Application temperature on inquiry, dependent on sensor and protective tube material Thermo junction J (Fe-CuNi) DIN EN K (NiCr-Ni) DIN EN on inquiry Number of Thermo junction 1 thermocouple 2 thermocouples Measuring point design insulated of protective tube connected to protective tube disconnected bead at 2 thermocouples connected bead at 2 thermocouples Protective tube material on inquiry Protective tube diameter d on inquiry mm Insert length L 1 on inquiry min. length of thread mm Type of connection cable on inquiry Cable length L 2 on inquiry min. 100 mm Bend protection without with spiral spring Thread M10 G1/4A G1/2A on inquiry Issue of 10/2013 Subject to change without notice electrotherm Gesellschaft für Sensorik und thermische Meßtechnik mbh Gewerbepark 6, D Geraberg Tel.: Fax: (0) (0) info@electrotherm.de

149 Thermocouples Cable sensors Series K5T Connector free ends connector on inquiry declare desired temperature range for case of application Issue of 10/2013 Subject to change without notice electrotherm Gesellschaft für Sensorik und thermische Meßtechnik mbh Gewerbepark 6, D Geraberg Tel.: Fax: (0) (0) info@electrotherm.de

150 SECTION 5

151 E2/20174 Quad-Power III Gates new generation raw edge V-belts Because of today s increasing maintenance and energy costs, industry is becoming more aware of ways to improve efficiency and reduce operating expenses. Eliminating losses in power transmission systems can translate into large savings. Gates leads the way in the development of cost and energy efficient belt drive systems and now brings you its new generation of Quad-Power III notched raw edge narrow section V-belts. Gates Quad-Power III belts deliver higher power ratings, increased trouble-free service life and reduced energy consumption. A high-performance, reliable and efficient drive is what you get when you choose Gates Quad-Power III belt drives

152 QUAD-POWER III Gates new generation raw edge V-belts The Gates Quad-Power belt has undergone several evolutions in design since its introduction over 15 years ago. New materials and advanced-design features have led to a new generation of Quad-Power III V-belt drives that outperform all similarly sized belt drives in a wide range of applications, yielding cost advantages for users, and greater design freedom for engineers. Construction features The basic belt consists of a newly developed rubber compound which withstands chemically aggressive environments (acid and base), ageing, ozone, UV and heat. Even with severe slippage, the belt will not catch fire from heat build-up. High-performance fibres embodied in the compound provide improved abrasion and wear resistance. The outstanding cord support in the undercord section achieved by the transverse orientation of the fibres reinforces the belt s overall longitudinal flexibility and transverse rigidity. The special notch profile with optimised geometry ensures perfect belt stability. The precision-ground sidewalls give a uniform wedging action. The tensile section consists of high-strength, low-elongation polyester tensile cords which are embedded in a newly developed blue-coloured adhesion layer. This layer develops an extra high bonding level between tensile cords and undercord material. The exceptional flexibility gives the belt excellent reversed bending properties when backside idlers are used. high-strength low-elongation polyester tensile cords embedding adhesion layer special notch profile fibre-reinforced rubber compound

153 QUAD-POWER III Additional benefits Extended temperature range: from -40 C up to +110 C. Extraordinary power capacity: at least 15% higher power ratings than Gates Quad-Power II belts. Substantially reduced noise level. Static conductive (ISO 1813) and can as such be used in the conditions described in the Directive 94/9/EC - ATEX. REACH and RoHS compliant. High dimensional precision. All sizes meet and even exceed Gates UNISET tolerances and can be installed without matching. Smooth-running operation. Space savings and design freedom. Minimal belt tension loss. Long and trouble-free service life reducing replacement and maintenance costs. Environment-friendly: halogen-free (e.g. chlorine). Significantly better resistance to static ageing. Taken together, these benefits result in a top quality, high-performance, low-maintenance V-belt drive that reduces the material and labour cost of maintenance, while at the same time improving uptime and productivity. Performance * Noise level Relative performance dba * These results were obtained under extreme test conditions. Sections and nominal dimensions * Width (mm) Height (mm) XPZ/3VX 10 8 XPA XPB/5VX XPC * As described in the ISO standards, nominal dimensions define the pulleys for which these belts are suitable. They do not represent the exact belt size. These are determined by the belt construction and are Gates proprietary.

154 Belt range XPZ/3VX ISO description Datum length mm RMA description XPZ VX238 XPZ VX250 XPZ VX252 XPZ VX262 XPZ VX265 XPZ VX272 XPZ VX280 XPZ VX286 XPZ VX289 XPZ VX292 XPZ VX297 XPZ VX300 XPZ VX305 XPZ VX311 XPZ VX315 XPZ VX321 XPZ VX331 XPZ VX335 XPZ VX341 XPZ VX346 XPZ VX350 XPZ VX355 XPZ VX360 XPZ VX366 XPZ VX370 XPZ VX375 XPZ VX380 XPZ VX385 XPZ VX387 XPZ VX390 XPZ VX395 XPZ VX400 XPZ VX407 XPZ VX410 XPZ VX419 XPZ VX425 XPZ VX429 XPZ VX439 XPZ VX442 XPZ VX450 XPZ VX454 XPZ VX459 XPZ VX464 XPZ VX469 XPZ VX475 XPZ VX479 XPZ VX487 XPZ VX494 XPZ VX498 XPZ VX500 XPZ VX505 XPZ VX508 XPZ VX518 XPZ VX520 XPZ VX530 XPZ VX538 XPZ VX553 XPZ VX557 XPZ/3VX ISO description Datum length mm RMA description XPZ VX560 XPZ VX567 XPZ VX572 XPZ VX587 XPZ VX592 XPZ VX597 XPZ VX600 XPZ VX607 XPZ VX612 XPZ VX626 XPZ VX630 XPZ VX650 XPZ VX666 XPZ VX670 XPZ VX690 XPZ VX710 XPZ VX730 XPZ VX750 XPZ VX771 XPZ VX790 XPZ VX800 XPZ VX836 XPZ VX850 XPZ VX883 XPZ VX900 XPZ VX931 XPZ VX950 XPZ VX986 XPZ VX1000 XPZ VX1045 XPZ VX1060 XPZ VX1104 XPZ VX1120 XPZ VX1180 XPZ VX1242 XPZ VX1320 XPZ VX1400 XPA ISO description Datum length mm XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA

155 XPA ISO description Datum length mm XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPA XPB/5VX ISO description Datum length mm RMA description XPB VX398 XPB VX422 XPB VX430 XPB VX445 XPB VX470 XPB VX497 XPB VX500 XPB VX524 XPB VX530 XPB VX556 XPB VX560 XPB VX575 XPB VX595 XPB VX600 XPB VX615 XPB VX630 XPB VX634 XPB VX654 XPB VX670 XPB VX674 XPB VX693 XPB VX713 XPB VX733 XPB VX753 XPB VX772 XPB VX790 XPB VX800 XPB VX840 XPB VX850 XPB VX886 XPB VX900 XPB VX910 XPB VX934 XPB VX953 XPB VX990 XPB VX1000 XPB VX1050 XPB VX1060 XPB VX1108 XPB VX1123 XPB VX1146 XPB VX1180 XPB VX1186 XPB VX1245 XPB VX1312 XPB VX1323 XPB VX1359 XPB VX1400 XPB VX1481 XPB VX1579 XPB VX1678 XPB VX1776 XPB VX1875 XPB VX1973 XPC ISO description Datum length mm XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC XPC Quad-Power III ordering code is composed as follows: XPZ600 XPZ - Section Datum length (mm) All dimensions are available from stock.

156 QUAD-POWER III The Quad-Power III alternative A Quad-Power III V-belt drive system offers innumerable cost saving advantages for both engineers and end-users. When designing a drive, design engineers should not only consider the end-user s equipment acquisition cost, but also the total cost of ownership and customer satisfaction. A belt drive system that minimises maintenance and replacement of components can not only save money in the long run, but also increase uptime and productivity. Design engineers can obtain a competitive advantage by integrating the Quad-Power III drives in their next power transmission application, since they will be able to provide end-users with better-performing and longer-lasting products that operate at a significantly lower overall cost. Furthermore, the increased power ratings allow smaller drives and therefore highly economical drive designs. While initial costs of standard construction V-belts can be quite low, the cost of maintaining these drives can be substantial. The labour costs to perform maintenance operations, combined with the associated downtime and lost productivity, represent a significant investment in time and money. For maintenance engineers and end-users, Quad-Power III drives can substantially reduce day-to-day operational costs. They can also increase production output by eliminating downtime and lost productivity resulting from all-too-frequent maintenance and replacement of defective drive components. Replace your existing drive technology with a Quad-Power III V-belt drive system from Gates and watch how your equipment and machinery gain a competitive edge in the market. Your distributor: The manufacturers reserve the right to amend details where necessary. Gates Corporation 2009 Printed in Belgium - 09/09.

157 V-belt pulleys for Taper Bushes BIRN is one of the biggest producers of Vbelt pulleys and flexible couplings. BIRN stocks a wide range of v-belt pulleys in diameter 50 to 1250 mm in SPZ, SPA, SPB og SPC from 1 10 grooves. All pulleys are treated with rust preventive ACC. The latest addition is the internationally patented VTP -Pulley, a V-belt pulley in a completely new design incorporating all aspects of optimized performance of V-belt pulleys. One of the improvements most worthy of mention is a combination of design and quality castings which has resulted in a weight reduction of up to 50 % compared to conventional V-belt pulleys. Furthermore, due to the tilted spokes, the internal tensions of the V-belt pulley are reduced considerably. The iron quality GGG 600 allows the circumferential speed to be increased up to 100 m/sec. and the resistance to wear of the V-belt pulley against the belt is improved. Increases the life of the V-belts due to the ventilated grooves resulting in lower working temperatures (10 C-17 C). Lower weight means less moments of inertia and requires smaller bearings. Also logistic costs are reduced. Is made in nodular cast iron with a new design resulting in smaller tensions in the pulley. VTP -pulleys make it possible to use the V-belt transmissions at higher ambient temperatures. Shock resistant, diminishing risk of damage during transport and mounting. Allows more than a doubling of the belt speed (up to 100 m/s). New surface treatment. ACC Autophoretic Coating Chemicals ensures improved rust protection.

158 Specifications SPZ SPA SPB SPC Dm mm ang. deg. <= > <= > <= > <= > lp mm h mm b mm f mm e mm 8, , ,5 12, , ,5 MATERIAL All cast iron used for the Taper Bush pulleys is electrically melted quality cast iron. This gives the iron an increased degree of purity and quality. Electrically melted iron contains only a minimum of contaminating matters as e. g. phosphor and sulphur. Therefore it has a very close-grained structure without microporosities. Because of the high degree of purity, gas holes in the cast iron are avoided. Taper Bush Pulleys are surface treated with Autophoretic Coating Chemicals to ensure rust protection. BALANCING Taper bush pulleys with solid hub are supplied with a max. static unbalance, balanced in one plane, according to quality grade G16 1). Upon request the pulleys can be supplied balanced in two planes, dynamic unbalance, according to quality grade G16 or G6,3. 1) Designation according to ISO 1940

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173 Baldor Electric Co Athens Design Engineering 197 Collins Industrial Drive Athens, Ga SPECIAL MOTOR DATA L10 BEARING LIFE INFORMATION CUSTOMER: JOHN BRIDGE SONS INC / 9TH & PENNELL/ CHESTER, PA ORDER NUMBER: FRAME: 365T HP: 75 HP RPM: 3600 ENCL: TEFC CALCULATED BEARING LIFE * SHAFT LOAD: 454 lb f * L10 LIFE: > 100,000 Hours *NOTE: This is a calculated, statistical life expectancy, to the specified L10 Life, if properly lubricated and maintained. Industrial practice shows only 8% of bearings reach predicted L10 Life expectancy. The other 92% fail prematurely because of impurities, lack of lubrication, misalignment, vibration, corrosion, etc. Compliance with L10 requirements should, therefore, not be construed as a guarantee that 90% of motors will exceed life specified as 50,000 hours or more. Data by: Bryan Chaffin Approved by: Bryan Chaffin Date:04/07/16 Date:04/07/16

174 The v-belt service factor is selected from a table (see below) based on the nature of the load and type of driving unit. Following is the calculation in which the belt service factor has been used to calculate design power.