Cyclon Series User Manual C20160-1576, Issue 3, March 1997 USER MANUAL CYCLON 330-345 AIR COMPRESSORS Serial Numbers from: Cyclon 330 F166/0101 Cyclon 337 F167/0151 Cyclon 345 F168/0101 CONTENTS Page 1. Safety Procedures Illustrations Page 5 Control Panel 13 2. General Description 11 Air/Oil System 15 3. Leading Particulars 19 Regulation System On/Off Control 16 4. Installation 21 Regulation System Modulating Control 17 5. Commissioning 25 Negative Regulator Settings 33 6.
CompAir BroomWade Limited OWNERSHIP DATA TECHNICAL DATA MODEL: Air-end Serial Number: Serial Number: Motor Serial Number: Year: Reclaimer Certificate Number: Maximum Pressure: Delivery Date: kW: Motor rpm: Compressor Lubricant: V. Ph. Hz.
Cyclon Series User Manual MODEL DESIGNATION The Model Designation code identifies specific models as follows: DESIGNATION CYCLON 3 3 0 0 7 A B B C C ➤ A = AIR-END SIZE B = MOTOR RATING (kW) C = NOMINAL DELIVERY PRESSURE CYCLON 3 30KW 7·5 BAR(110PSI) This publication relates to all standard operating pressure versions of the following models: Cyclon 330 Cyclon 337 Cyclon 345 ASSOCIATED PUBLICATIONS Model Title Part No.
CompAir BroomWade Limited WARRANTY The conditions of the CompAir BroomWade Warranty are set out in the company’s standard Conditions of Sale available from the Distributor supplying the machine. ! ! ● The use of replacement parts or lubricating oils not supplied or approved by CompAir BroomWade may lead to failures in service which would not be covered by warranty.
Cyclon Series User Manual 1 SAFETY PROCEDURES Page General 6 Warnings, Cautions and Notes 6 General Safety Precautions 7 Installation Precautions 7 Operational Precautions 7 Maintenance and Repair Precautions 8 Precautions in the Event of Fire 9 page 5
CompAir BroomWade Limited SAFETY PROCEDURES 1. GENERAL Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially hazardous. 2. WARNINGS, CAUTIONS AND NOTES 2.
Cyclon Series User Manual – Safety Procedures 3. GENERAL SAFETY PRECAUTIONS If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing and eye protection is worn. Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing. Before releasing compressed air through a hose make sure that the free end is held securely so that it cannot whip and cause injury.
CompAir BroomWade Limited Do not open the starter compartment or touch electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools and wearing appropriate body protection against electrical hazards. On a unit equipped with an Automatic Start/Stop system, attach a sign stating ‘THIS UNIT MAY START WITHOUT WARNING’ next to the display panel.
Cyclon Series User Manual – Safety Procedures Use only lubricating oils and greases approved by CompAir BroomWade. Make sure that the selected lubricants comply with all relevant safety regulations, especially with regard to the risk of explosion or fire and the possibility of decomposition or the generation of hazardous gases. After completion of repair or maintenance work ensure that no tools, loose items or rags are left on or inside any part of the machine.
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Cyclon Series User Manual 2 GENERAL DESCRIPTION Page Compressor 12 Air-End 12 Electronic Controller 12 Protection and Safety Equipment Relief Valve Blowdown System Minimum Pressure Non-return Valve 12 12 12 12 Air/Oil System Description Operation 14 14 14 Regulation System Description On/Off Control Modulating Control (Optional) 16 16 16 17 page 11
CompAir BroomWade Limited GENERAL DESCRIPTION 1. COMPRESSOR 3. ELECTRONIC CONTROLLER The unit is a fully enclosed, air cooled, singlestage, rotary screw compressor. The compressor air-end is belt driven by an electric squirrel-cage induction motor. The drive belts are mounted on pulleys fitted to the shafts of the drive motor and air-end. The electronic control system is microprocessor based with an LED display panel, incorporating advanced control and monitoring features.
Cyclon Series User Manual – General Description P2 T1 °C P1 bar D1 L1 L2 L3 L4 L5 L6 L7 L8 L9 B1 B2 B3 B4 B5 B6 D1 E B1 P1 bar B2 E T1 °C B3 P2 B4 B5 B6 View Start Stop Plus Minus Reset Display Emergency Stop Button L1 L2 L3 L4 L5 L6 L7 L8 L9 Pressure (Delivery) Temperature Hours Run Hours Onload Air Filter Alarm Motor Fault Auto/Remote Start Running Power On CONTROL PANEL page 13
CompAir BroomWade Limited 5. AIR/OIL SYSTEM 5.1 Description The air/oil system comprises an air intake filter, suction regulator, air-end, oil separator vessel, oil separator filter, minimum pressure/non-return valve, aftercooler, oil cooler with thermostatic bypass valve and an oil filter. The flow of oil through the circuit is achieved through the pressure differential existing between the primary oil separator and the oil injection point in the air-end. 5.
Cyclon Series User Manual – General Description 10 3 8 14 6 9 11 12 1. 2. 3. 4. 5. 6. 7. 2 7 1 Suction Regulator Intake Air Filter Minimum Pressure/NR Valve Primary Oil Separator Oil Separation Element Discharge Pipe Air-end 5 8. 9. 10. 11. 12. 13. 14.
CompAir BroomWade Limited 6. REGULATION SYSTEM 6.1 Description suction regulator inlet valve fully open, or off-load with the inlet valve fully closed. The compressor is regulated through a combination of electronic, pneumatic, electrical and mechanical devices. Two modes of regulation are used: ‘On/ Off’ is fitted as standard, and ‘Modulating’ as an optional extra. 6.2 When the controller switches the compressor to run off-load, a run-on time sequence is activated.
Cyclon Series User Manual – General Description 6.3 Modulating Control (Optional) In the ‘Modulating’ mode the opening and closing of the suction regulator inlet valve is controlled by the negative regulator. As the demand for compressed air rises and falls, the valve modulates between fully open and fully closed. When the compressor is started and runs up to load, the minimum pressure valve opens and air under pressure passes from the separator vessel into the user’s pipework.
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Cyclon Series User Manual 3 LEADING PARTICULARS page 19
CompAir BroomWade Limited LEADING PARTICULARS Model Air-end Cyclon 330 Single stage oil injected screw Total oil capacity: Delivery air connection: litres without optional flexible pipe with optional flexible pipe Ambient air temperature Minimum operating range: Maximum Delivery air pressure: Cyclon °C °C Minimum (all models) bar Maximum (see compressor data plate) bar Cyclon 337 Cyclon 345 3 3 3 17·0 17·5 18·5 Rp 1 1/2 R 1 1/2 Rp 1 1/2 R 1 1/2 Rp 1 1/2 R 1 1/2 0 46 0 46 0 46 5 7
Cyclon Series User Manual 4 INSTALLATION Page Guidelines 22 Installation Procedure 23 page 21
CompAir BroomWade Limited INSTALLATION ! ● 1. WARNING Refer to the safety procedures before installation of the compressor unit. GUIDELINES Study the installation information in the manual for the particular compressor concerned. The compressor unit is supplied as a complete package and does not need securing to a foundation. However, the supporting floor must have a loading capacity sufficient to support the weight of the unit (see ‘Leading Particulars’).
Cyclon Series User Manual If the compressor is to be coupled in parallel with another compressor or connected to an existing air supply system, additional steps must be taken as set out in the ‘Safety Procedures’ section of this manual. 5. A gland plate is fitted to the RH side of the starter box. Open the starter door and rotate the gland plate to the appropriate gland size, or remove the plate and and drill a hole to the required size in the spare space.
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Cyclon Series User Manual 5 COMMISSIONING Page Commissioning Procedure Preliminary Checks Pressure Calibration Checking/Altering Program Mode Values Final Checks 26 26 27 28 30 Negative Regulator (Modulating Control Only) 33 Commissioning Checklist 34 page 25
CompAir BroomWade Limited COMMISSIONING ! ● 1. WARNING Refer to the safety procedures before commissioning the compressor unit. COMMISSIONING PROCEDURE When commissioning a new compressor or recommissioning a compressor which has been out of service, carry out the following procedures before attempting to start: ● Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. 6.
Cyclon Series User Manual – Commissioning 1.2 Pressure Calibration Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with the compressor model. No. Action Reason Display 1. Switch power ‘ON’ at the isolator and allow the controller to initialise. 0.0 Bar 2. Press the STOP button. even if the compressor is already stopped. 0.0 Bar 3. Disconnect the air pipe from the pressure transmitter. To apply 0.0 Bar to the pressure transmitter 0.
CompAir BroomWade Limited 1.3 Checking/Altering Program Mode Values Note: The values shown throughout these procedures are examples only. Ensure set values relate to compressor model. No. Action 1. Switch power ‘ON’ at the isolator and allow the controller to initialise. 0.0 Bar 2. Press the STOP button, even if the compressor is already stopped. 0.0 Bar 3. Press and hold the PLUS and MINUS buttons together. 4. After five seconds indicators L1 to L8 will flash four times.
Cyclon Series User Manual – Commissioning No. Action Reason Display 14. Press PLUS or MINUS or go to step 16 if no adjustment required. To adjust the displayed value 1500 Press STOP To program the new value into the controller memory 15. (pulsing display) 1500 (steady display) 16. Press VIEW 17. Indicator L4 will light and the display will show the solenoid valve 'open' time setting. 18. Press PLUS or MINUS or go to step 20 if no adjustment required.
CompAir BroomWade Limited No. Action Reason 28. Press VIEW To step to the next option 29. Indicator L7 will light and the display will show the Auto restart delay time. 30. If the auto restart facility is required press PLUS or MINUS. If the facility is not required set the display to 0 seconds, this will disable the facility. Press STOP 31.
Cyclon Series User Manual – Commissioning No. Action 3. Press STOP as soon as the motor begins to rotate. Reason Display 0.0 Bar CAUTION: Do not allow prolonged running in the reverse direction as damage will be caused. 4. If the direction of rotation ( marked by an arrow on the inside of the service panel) is incorrect, isolate the power supply and change over motor connections U1 and V1 on the main contactor and connections U2 and V2 on the delta contactor. Return to step 1. 5.
CompAir BroomWade Limited No. Action 13. Check that the compressor automatically re-starts when pressure falls below the lower pressure set point P2. 14. Run the compressor for 30 minutes. Check for air/oil leaks. (It will be necessary to remove the enclosure panels for short periods). Stop the compressor and rectify any leaks. ! WARNING: RISK OF HIGH PRESSURE Do not use hands to locate leaks in the system. Always use a piece of paper or card for this purpose. 15.
Cyclon Series User Manual – Commissioning 2. NEGATIVE REGULATOR (Modulating Control Only) During commissioning or after a period it will be necessary to adjust the delivery air pressure and the negative regulator as follows: 1. Open the shut-off valve to the user’s pipework. 2. Create a downstream air bleed to simulate a demand for air by opening the drain valve of the downstream air receiver, if installed, or opening a valve in the user’s pipework. 3.
CompAir BroomWade Limited 3. COMMISSIONING CHECK LIST 1. Protective blanks and tapes removed. 2. ............ 3. All electrical connections checked. ............ 4. All control system connections checked. ............ Cable and fuse ratings comply with regulations. ............ 6. Pressure set-points set. ............ 14. Controller model option set. ............ 15. Regulation air system isolating valve open. ............ 16. Oil drain valve closed. ............ 17.
Cyclon Series User Manual 6 OPERATION Page Routine Operation Starting Standby Mode Stopping Emergency Stop Oil Temperature and Hours Run Display Service Interval Timer Alarms and Shutdown Trips Power Supply Failure Detection Control Panel Indicators 36 36 36 37 37 37 37 38 39 39 Program Mode Program Mode Routine Program Mode Setting Definitions Program Mode Settings Fixed Parameters 40 40 41 41 42 Pressure Calibration Mode Pressure Calibration Routine 42 42 Control Function Options Automatic Restart
CompAir BroomWade Limited OPERATION ! ● ! WARNING Refer to the safety procedures before operating the compressor unit. 1. ROUTINE OPERATION 1.1 Starting 1. Switch mains power ON at the isolator. The display will show the control program identification and the Power on indicator (L9) will light. 2. After a few seconds the Delivery pressure indicator (L1) will light and the display will show the delivery pressure in Bar. See para 1.5 ‘Oil temperature and Hours run display’. 3.
Cyclon Series User Manual – Operation 1.3 1. 2. Stopping To stop the compressor press STOP (B3). This initiates a controlled shut down sequence. The compressor will unload, the drive motor will stop and the Start indicator (L8) will flash slowly for the blowdown period. See para 2.3 ‘Program mode settings’. The compressor motor cannot be re-started during the blowdown sequence.
CompAir BroomWade Limited 1.7 Alarms and Shutdown Trips 1. If an alarm condition occurs and service attention is required the appropriate alarm indicator will flash. 2. If a trip condition occurs the compressor will stop and the appropriate trip indicator will flash. This can occur any time after the compressor has been started. See para 1.9 ‘Control panel indicators’. 3. The oil temperature alarm and oil temperature trip conditions are shown by indicator (L2) flashing.
Cyclon Series User Manual – Operation 1.8 Power Supply Failure Detection The controller is equipped with a power supply failure detection facility. If a power supply failure is detected, the compressor will stop, the controller will reset, and the display will show three horizontal lines in the left hand side of the display after the controller has re-initialised. If the power failure Auto-restart facility is enabled, the compressor will automatically restart.
CompAir BroomWade Limited 2. PROGRAM MODE 2.1 Program Mode Routine 6. ‘Program mode’ is used to access, view and/or alter the operating parameters and options stored in the memory of the controller. 1. 2. To enter the ‘Program mode’ press STOP (B3) then press and hold PLUS (B4) and MINUS (B5) together. After five seconds indicators L1 to L8 will flash four times to indicate that the controller has entered ‘Program mode’. Release PLUS and MINUS buttons when the indicators start to flash. 3.
Cyclon Series User Manual – Operation 2.2 Program Mode Setting Definitions Indicator 2.3 Setting Description L1 Pressure set point P1 Pressure at which the compressor will unload. L2 Oil temperature trip Temperature at which the compressor will shut down and indicate a high oil temperature trip. (The oil temperature alarm is set automatically at 10°C below the trip) L3 Service interval time Maximum service interval time.
CompAir BroomWade Limited 2.4 Fixed Parameters 4. After five seconds indicators L1 to L8 will flash four times to indicate that the controller is now in pressure calibration mode. Release PLUS (B4), MINUS (B5) and STOP (B3) when the indicators start to flash. 5. The display will show 0.0 Bar. If the pressure transmitter signal is outside of acceptable limits. The controller will automatically return to normal running mode and display a pressure transmitter fault. 6.
Cyclon Series User Manual – Operation 4. CONTROL FUNCTION OPTIONS 4.2 4.1 Automatic Re-start 4.2.1 Remote Start Automatic re-start will allow the compressor to start automatically after a break or failure in the mains power supply. When this facility is enabled the Remote start / Auto re-start indicator (L8) will be lit. 1. To enable Automatic re-start select an Automatic restart delay time of greater than zero seconds using the ‘Program Mode’. 2.
CompAir BroomWade Limited X01-4 X01-7 X2/1 X2/2 Controller Start N/O Stop N/C REMOTE START/STOP X01-6 X01-5 X2/1 Controller Remote pressure switch or cascade panel REMOTE LOAD/UNLOAD 2. When this option is selected the compressor will load when terminal X01, pin 6 is connected, via a remote pressure switch, cascade control panel or other switching device, to terminal X2/1. page 44 3. The compressor will unload when the connection between X01, pin 6 and X2/1 is broken.
Cyclon Series User Manual – Operation 4.4 Remote Group Fault Output 4.4.3 Group Fault Relay - Example 4.4.1 Group Fault Relay The control card is fitted with a group fault relay, the relay contacts being available for switching remote facilities. The relay contacts are rated for a maximum of 250V ac at 5A and are connected to controller terminal X08, pins 9 and 10. 4.4.
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Cyclon Series User Manual 7 MAINTENANCE Page Routine Maintenance Cleanliness Recording Pressures and Temperatures Maintenance Record Electrical Connections Leaks Lubricating Oil 48 48 48 48 48 48 48 Maintenance Schedule Separator Element Part Number Table Service Kit Part Number Table Drive Belt Part Number Table (50Hz) Drive Belt Part Number Table (60Hz) 49 50 50 50 50 Maintenance Procedures Enclosure Filter Air Intake Filter Oil Separator Filter Oil System Drive Belt(s) Electrical System Electric Mot
CompAir BroomWade Limited MAINTENANCE ! ● 1. WARNING Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. ROUTINE MAINTENANCE To ensure efficient operation of the compressor the performance must be checked regularly and adjustments made to maintain the correct settings. This section gives the information needed for this purpose. ● Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks.
Cyclon Series User Manual – Maintenance 2. MAINTENANCE SCHEDULE Regular maintenance should be carried out by your local CompAir BroomWade distributor as detailed in the Maintenance Schedule. The Schedule should be used as a general guide only. Item Action Weekly Oil System Separator Element Aftercooler Check oil level. Top up if necessary. Check separator element. Renew if on load pressure differential is 1 bar or above. Check condition of pre-filter and clean as necessary.
CompAir BroomWade Limited 2.1 Separator Filter Part Number Table Model Cyclon Qty. 330/337 345 1 2 Max Rated Pressure (Bar) Separator Filter 7·5 to 13 7·5 to 13 98262-223 98262-223 2.2 Service Kit Part Number Table USE ONLY GENUINE PARTS Model (Cyclon) Service Kit Major Service Kit 330/337 345 CK2003-2 CK2003-2 CK8003-2 CK8003-3 AUTHORISED SERVICE AGENTS Note: Use Service and Major Kit for Major Service requirements 2.3 Drive Belt Part Number Table (50 Hz) Model 330 337 345 Qty.
Cyclon Series User Manual – Maintenance 1. 2. 3. 4. 5. 6. 7. 8. Intake Air Filter Suction Regulator Oil Cooler Drive Belt Motor Bearings Minimum Pressure/Non-return Valve Separator Element Oil Filter Element 9. 10. 11. 12. 13. 14. 15. 16.
CompAir BroomWade Limited 3. MAINTENANCE PROCEDURES ! ! WARNING ● Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit. ● Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. ● 3.1 1. Close the shut-off valve to the user’s pipework. 2. Switch the power supply ‘OFF’ at the isolator. 3.
Cyclon Series User Manual 3.3.1 To Change the Separator Filter: 3.4.2 To Check the Oil Level: The compressor must be stopped. To view the oil level sightglass, remove the front panel of the plant. 1. Open the door to the service area to gain access to the manifold block. Note: Cyclon 345 has two separate filters both of which must be changed at the same time. 2. 3. 4. 5. 3.4 Unscrew the old separator filter(s) from the manifold block and discard the filter and sealing ring.
CompAir BroomWade Limited 3.4.3 To Change the Oil Filter: 3.4.5 To Change the Oil: The compressor must be stopped. 1. Open the door to the service area. To drain the oil, the system must (a) be pressurised or (b) an alternative source of compressed air must be available. 2. Unscrew the old oil filter from the manifold block and discard. CAUTION: Always use the correct grade of oil and do not mix oils of different types. 3.
Cyclon Series User Manual – Maintenance 11. Apply a film of clean oil to the seal of a new oil filter element. Screw the element into the housing until it contacts the gasket and tighten a further 1/3 turn. 9. Remove the air supply and fitting from the filler tube. 12. Fill the separator to the correct level with BroomWade approved lubricant, refit the filler cap and tighten by hand. 11. Apply a film of clean oil to the seal of a new oil filter element.
CompAir BroomWade Limited 3.5.1 Adjustment After Fitting New Drive Belt(s): 3. Start the compressor and run for 5 minutes. Remove excess grease and refit the dust caps. 1. Release the 1/4 turn fasteners and remove the LH side panel. 4. 2. Loosen the lock nut (1) and turn the nut (2) clockwise until the adjuster (3) contacts the cut-out in the spring retainer (4). 3.7.2 3. Screw the nut (2) back one turn and tighten the lock nut (1). 4.
Cyclon Series User Manual 8 FAULT FINDING Page Fault Indications Trip Fault Indications Alarm Fault Indications 58 58 59 Shutdown Faults 59 Alarm Faults 60 page 57
CompAir BroomWade Limited FAULT FINDING In operation the compressor is protected by circuits which are triggered when a fault arises and either cause the compressor to shut down or indicate that a servicing action is required. ! ● ! WARNING Refer to the safety procedures before carrying out any fault finding investigation on the compressor unit. 1. FAULT INDICATIONS 1.1 Trip Fault Indications ● Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks.
Cyclon Series User Manual – Fault Finding 1.2 2. Alarm Fault Indications Display Meaning L2 Flashing Slowly High Temperature L3 Flashing Slowly Service Due L5 Flashing Slowly Change air filter SHUTDOWN FAULTS Fault Possible Cause Action Required Emergency Stop (1) Emergency Stop Switch operated. (1) Establish reason and rectify. Turn Emergency Stop switch to release latch and Press RESET. Excess Pressure (1) Compressor failed to unload.
CompAir BroomWade Limited Fault Temperature sensor failure Possible Cause (1) Wire Connections. (2) Sensor failure. High Oil Carry Over Drive Motor Fault (1) Separator element. (2) Oil Drain Valve (1) Overload relay incorrectly set. (2) Insufficient cooling air flow. (3) High ambient temperature. (4) Low voltage/high current. 3. Action Required (1) Check all temperature sensor circuit wire connections. (2) Renew sensor. (1) Fit new element. (2) Check valve closed.
Cyclon Series User Manual APPENDIX 1 Electrical Connections page 61
KM101 E F101 U2 V2 W2 M101 3~ U1 V1 W1 a b 101 102 F1 F2 F101 KM101 KM102 KM103 M101 P201 KM102 0V 24V EARTH BAR 0V 105 3·15A F2 X1/2 X1/2 106 Fused Terminal 1·6A Fused Terminal 3·15A Motor Overload Relay Main Contactor Star Contactor Delta Contactor Drive Motor Pressure Sensor 102 415/380V 220/230V S101/1 Q101 101 108 X1/1 109 V W PE X1/1 X1/2 X1/2 X1/2 X1/1 X1/1 7 8 X1/1 3 4 X1/1 1 2 X08 5 6 RELAY OUTPUTS X1/2 X1/1 X1/3 X1/2 Q101 R201 S101 S201 T101 Y101 Y102 X1
Cyclon Series User Manual APPENDIX 2 The Pressure Systems and Transportable Gas Container Regulations 1989 page 63
CompAir BroomWade Limited APPENDIX 2 Note: The intervals between examination and calibration of components, eg pressure vessels, pressure relief valves etc, will be defined by the ‘competent person’ preparing the written scheme. THE PRESSURE SYSTEMS AND TRANSPORTABLE GAS CONTAINER REGULATIONS 1989 The circuit diagram shown below is provided to assist a ‘competent person’ in preparing a written scheme of examination for a system incorporating the air compressor(s).
Cyclon Series User Manual 5 4 6 3 7 2 + 8 1 9 15 10 M 11 14 1. 2. 3. 4. 5. 6. 7. 8. 13 Air Intake Filter Suction Regulator Venting Valve Negative Regulator Unloader Solenoid Valve Shuttle Valve Pressure Transmitter Aftercooler 16 12 9. 10. 11. 12. 13. 14. 15. 16.
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