CURTIS – TOLEDO - Air Compressors Direct
Contents
1. 1 Compressor is powered up Screen digital displays show the oil t external amp Sump pressure power usage of main motor Messages Drive Stopped Compressor Unloaded 2 Press START key to start compressor 3 Main screen messages in different operation modes FIG 31 35 1 Press the MENU key FIG 1 to see all menu options 2 Press the CLOSE key to return to FIG 1 Note menu can be browsed any time whether Isera compressor is in stop or run mode Warni nas Dil Temp F Compressor Loaded 1 Press the SERVICE key FIG 2 to get Compressor amp Service Statistic screen Screen a A ca shows actual hours remaining until service required run load hours SE 2 Press appropriate Reset key after service has 1999 been completed to reset hours FIG 4 3 Press Adjust Hours key to set service hours 3999 Separator DEP RESET different less than factory setting FIG 5 r999 FIG 3 SERVICE STATISTICS CAP320 1 Press YES or NO on pop up screen after appropriate Reset key is pressed to reset hours of service Separator Counter TES 1 Press any digital display needs to be adjusted and numeric keypad will appear FIG 6 Separator Hours 1 Press the digits need to be entered look at upper right corner of keypad to make sure the right number was entered 2 Press ENTER CLR or ESC to enter number clear number2. 1 Press digital display amp using numeric keypad enter desirable oil temperature setpoint default temperature is 180 82 C Note fan drive will automatically adjust fan motor speed to hold oil temperature at setpoint 2 Press Back to return to screen FIG 39 CAP320 _ Cooling Fan Setup See description to FIG 39 FIG 42 COOLING FAN SETUP PARAMETER DOWNLOAD PROCESS 1 Press the Close key to return to screen FIG 39 FIG 43 COOLING FAN SETUP PARAMETER DOWNLOAD COMPLETE 22 CAP320 Securitu Logon FOR FACTORY PERSONNEL ONLY EE 1 On Security Logon screen FIG 24 press the 0 to get numeric keypad amp enter 4 digit password amp Factory Setup key will appear 2 Press this key to get Factory Access Setup screen FIG 45 1 Press digital display Compressor type Fan motor HP Shutdown Temp Pressure Shutdown amp use numeric keypad to change Lonpressor Type parameter seiting Fan Motor HP 2 Run Hrs amp Load Hrs digital displays are for information only This data cannot be reset from Shutdown Temp F field service or operator screens 3 Press Compressor Motor Configure kev to get Compressor Motor Nameplate Data screen FIG 46 Compressor BN Cool ing Fan Input 4 Press Cooling Fan Motor Configure key Motor Motor Conf igure to get Cooling Fan Setup screen FIG 39 Conf igure Configure Y To configure fan motor use screens amp descriptions to screens FIG 39 43
3. Pressure shutdown Note change the nameplate data amp run motor ID only if motor data has been changed 1 Enter motor nameplate data pressing each digital Motor ID display amp change value by using numeric keypad 2 When Motor ID Required flashing message will appear press Run Motor ID key to save new motor Bir e esche data on drive When Motor ID saved the Motor ID Complete message will appear 3 Press Motor Rotation Check key to check Motor the motors rotation only if motors have been nal Current Amps 2 As a Rotation changed Rotation Check Active message will Check appear amp motors will rotate slowly for 10sec 4 Press Back to return to screen FIG 45 amp press Input Configure key on screen FIG 45 to get Input Configure screen FIG 47 FIG 46 COMPRESSOR MOTOR NAMEPLATE DATA 23 CAP320 1 Press Norm Open or Norm Closed key to change drive inputs 2 8 configuration Input 2 Inscription on right column of screen will change accordingly RALE Closed Gee 2 Press Back to return to screen FIG 45 a E Harr Horm r Fri INPUT FI P LI t E Z pe di ei A bes n iS i 1 Input Input FIG 47 INPUT CONFIGURE 24 CAP320 3 DRIVE KEYPAD OPERATION In emergency situation when Touch Screen has failed the compressor START STOP function can be made from the compressor VFD keypad control panel mounted on the ACS800 drive Follow the instruction below
4. amp drive reset Active alarms or warnings are red amp 463 16 12 69 12 09 Drive Tripped historical are white Up to 200 messages stored in history 2 43 16 12 68 12 69 Drive Tripped 2 Press Up amp Down keys to scroll alarm s history 1 63 16 12 67 12 68 Drive Tripped 6 63716 12 07 12 69 Estop Iripped FIG 12 ALARMS amp WARNINGS HISTORY CAP320 1 Press the digits on numeric keypad need to be entered press ENTER Shutdown Temp 1 Compressor Mode Setup screen is designed to set different modes amp controls Constant or Auto to set operational mode ON or OFF to activate l remote control option amp Lead Lag control uto Mode Setup option l 2 Press Back Main or Next Page to switch among the screens Leag Laa control Pel 3 Disabled Mm Encbled gt Bi Em CI 1 Press Constant to set the constant speed mode Digital display amp Constant inscription will appear Press digital display amp enter desirable motor speed on numeric keypad 1206 Hater SS iul Note compressor can be switched from Auto to Constant during stop or run 2 To activate Lead Lag control set value using numeric keypad recommended setting 5psi Message Lead Lag Active on main screen will appear FIG 34 A 3 To activate remote control option press ON key a Enabled gt oi Inscription will change to Remote Start ON Message Start From Remote Site on main screen will appear FIG 35
5. AUTO mode Wake up pressure poe 7 Operating P TS Fig 19 Default Type 1 13 Table 4 Shutdown pressure 140psi O 215psi TS Fig 45 Default Type 5 Table 4 Oil temperature Actual t 225 F TS Fig 1 9 Displays actual temperature Shutdown i S La ue 225 194 240 TS Fig 37 45 Warning if t shutdn t 10 F Auto restart time D O 240sec TSFig 15 Manual 0 Auto 1 240 sec Stop delay time TS Fig 15 Default Type 1 13 Table 4 Blowdown time TS Fig 15 Default Type 1 13 Table 4 Cutout delay time TS Fig 19 Preset by program Standby delay time 0 5min 0 60min TSFig 19 Default Type 1 13 Table 4 TS Fig 19 Constant mode Motor min Motor Motor max TS Fia 18 Ges be sel Sen pil motor speed speed min speed ig motor speed range if constan speed mode applied TS Fig 18 Lead Lag operational if Lead Lag control Opsi Opsi 5psi TS Fig 18 differential pressure value has been set Oil temperature k 3 a l 180 160 240 TS Fig 27 Displays the setting TS Fig 20 TS Fig 20 Notes 1 Default setting as an example for this manual is type 5 see Table 2 2 Lead Lag control disables Remote start stop functionality 3 Lead Lag control installation setup and recommended setting see 1 5 1 3 2 Service and statistics Table 2 Parameter Name Default Min Max Display Remarks Oil filter 1000hrs 1000 hrs TS Fig 3 6 Warning message at 0 hrs Airfilter 2000hrs 2000 hrs TS Fig 3 6 Warning m
6. Control TDC of motor control system Fan VFD ACS550 AC drive ABB Inc utilize V Hz control method Touch screen TS is Operator Interface Terminal connected to compressor drive PLC Detail drives information safety amp maintenance instructions are described in ACS800 Hardware Manual ACS Firmware Manual 8 ACS550 User s Manual included in document s package of this unit 1 2 Software The ACS800 application consists of drive configuration parameter Groups and control Software is custom made for Curtis Toledo rotary screw compressors VFD Parameter Groups used for drive PLC programming appear on drive keypad Keypad must be used only ABB certified technical professionals Software provides the compressor operation in Pressure Pl loop control Compressor motor speed reflects the system air demand at designed operating pressure CAP320 1 3 Parameter tables 1 3 1 Basic parameters and settings Table 1 Parameter Name Default Min Max Display Remarks External pressure Actual psi D 1 200psi TS Fig 1 7 Displays actual pressure Actual psi D 1 200psi TS Fig 1 8 Displays actual pressure Calc Sump P Ext P DP pressure Calculated IC N A Warning if DP gt 10psi Load P Shutdown Unload pressure 125psi P 10psi TS Fig 15 Default Type 5 Table 4 105psi o P TSFig 15 Default Type 5 Table 4 Load P Unload P Default setting is calculated Operating pressure Unload P 2 5psi 5psi id Compressor is in
7. Notice the L on the display instead of the R To return to the REMOTE Mode Notice the R on the display nstead of the L To start the motor press the Start Button To stop the motor press the Stop Button Once pressed the motor ill continue running Unloaded for he Stop Delay Time 26 CAP320 1R gt 115 0 PSI EXT PRES XX x PSI SMP PRES Xx x PSI O L TEMP xxx F 1L gt 115 0 PSI EXT PRES Xx Xx PSI SMP PRES Xx X PSI O L TEMP xxx F 115 0 PSI xx x PSI XX X PSI xxx F 115 0 PSI xx Xx PSI XX x PSI xxx F 115 0 PSI xx x PSI XX X PSI xxx F CAP 320 4 MAINTENANCE 4 1 Introduction Maintenance procedure amp schedule for air filter separator element oil amp oil filter described in Rotary Screw Compressor Operation Instruction Manual 4 2 Control panel cooling fan exhaust filters Temperature 8 functioning of drives mounted inside of control panel depends on cooling fan filter condition Frequency of servicing the filter element will depend on the environmental conditions under which the compressor is operating Service the filter elements under any of the following conditions whichever comes first e Drive temperature exceeds 230 F Refer to Compressor VFD Status screen TS FIG 26 e Change every two thousand 2000 hours of operation or every six 6 months TS FIG 3 shows default setting 2000 hours e Under extremely dusty amp dirty ambient conditions change the elements
8. as required 2 CAP320 8 03 ail 1 55 Maximum depth Front View behind the FRONT of any panel 36 Panel mounting clamp 4 places oniv 1 shown Shielded DE9S female connector Shielded DE9P male connector FUSE Rear View Side View POWER MALE CONNECTOR FIG 48 TOUCH SCREEN DIMENSIONAL DRAWING 28 fF Hey H3 COOLING THERMOSTAT e O O 24 VDC RS485 U ACS800 HMI300 TOUCH SCR CONTROL PANEL EAD LAG CONTRO OPTIONAL TIMER SOURCE BY CUSTOMER N NON FUSED DISCONNECT SOPTIONAL 2 gt D i gt J Le JLLI IL aj j Cu ACSS50 A ba DDD LLI ILLI IL MAI d M x gt TY J JI N A lt N Sh OV FIG 49 WIRING DIARGRAM pg 1 29 CAP320 ACS350 D
9. numeric keypad to make time amp date adjustment Motor Amps when Compressor is Linl ocded i of Motor Full Load Amps 3 E Savings Run Hours Loaded Hrs Reset Reset Reset FIG 22 SETUP ENERGY SAVINGS Energy Savings TES U FIG 24 SETUP FACTORY CAP320 1 Press Energy Savings key on screen FIG 14 or Next Page key on Units Time Setup screen FIG 20 to get the Energy Savings Setup screen 2 Press digital display amp use numeric keypad to change parameters setting Note cycle analysis required to set parameters FIG 3 amp FIG 26 1 To reset Energy Savings FIG 26 Run amp Load Hours FIG 3 press appropriate reset key Confirm YES or NO on pop up screen 2 Press Main to return to main screen 1 Factory setup has multiple level of password protection Low order protection used by Field Service Personnel only High order protection used by Factory Engineering amp Testing Personnel only CAP320 1 Press COMP STATUS key on screen FIG 2 to see compressor status menu options 2 Press the CLOSE key to return to FIG 1 Note status menu can be browsed any time whether compressor is in stop or run mode 1 Press COMP VFD STATUS on menu FIG 25 8 screen with compressor data will appear Speed RPM Note Mains V actual voltage is displayed when compressor is running Torque 251 Current SARI Mains Cw 3 Consumet casi ion Lt Power Ce FIG
10. or close application without changes Note all numeric keypads used with other screens are typical FIG 6 SERVICE NUMERIC KEYPAD Ext Press Sump Press Dil Tempo FIG 7 METERS EXTERNAL PRESSURE Ext Press Sunp Press Dil Temp FIG 8 METERS SUMP PRESSURE Ext Press Sunp Press Oil Temp FIG 9 METERS OIL TEMPERATURE CAP320 1 Press the METERS key FIG 2 to get compressor output data in analog form Actual parameter values are the same as on main screen digital displays 2 Push Ext Press Sump Press or Oil Temp keys for analog display 3 Press Main key to return to screen FIG 1 See description to FIG 7 See description to FIG 7 CAP320 1 When New Alarm message is flashing on main screen there are two options to activate alarm definition press New Alarm message press MENU 4 press Alarms amp Warnings key FIG 2 Alarms amp Warnings screen will appear FIG 11 1 Screen shows active alarm or warning 2 Press History key to see Alarm History screen FIG 12 3 Press inscription to see pop up screen with explanation 8 recommendation FIG 13 d Press 8 hold Compressor Drive Reset after problem has been fixed all messages amp Drive Reset key should disappear 5 Press Main to return to main screen FIG 11 ALARMS 8 WARNINGS SCREEN Alarm History 1 Screen shows date amp time when system went to m alarm amp time when it went out problem fixed
11. to activate Standby sleep mode TS FIG 19 when the motor Minimum Speed Limit 10rpm is met CONTROL MODE has two selections Constant 8 Auto Constant Mode is used to run the compressor at a user defined Constant Motor Speed entered by TS numeric keypad TS FIG 18 and does not use Pressure Loop Control for speed regulation Auto Mode TS FIG 17 19 enables the Pressure Loop Control for compressor speed regulation based on External Pressure and holding the constant pressure makes the compressor produce the air to meet user air system demand REMOTE CONTROL enables Remote Start Stop optional device by selecting ON at TS Setup Mode TS FIG 17 When parameter is set to ON then the start command is no longer given by the TS Start key but a remote switch wired to terminals 11 15 Ref Wiring diagram FIG 49 Stop command still can be issued from TS TS FIG 35 LEAD LAG CONTROL is operation of two compressors By setting a value of zero TS FIG 17 the Lead Lag Control is disabled When a pressure value is set then the Lead Lag Control is activated An external hardware timer is used to alternate Lead Lag mode between two compressors Timer wired in accordance with Wiring diagram FIG 49 On both compressors the Lead Lag Control pressure value Load Unload amp Operating Pressure must be set the same On Lag Compressor the Operating Pressure will automatically change to a value of Pressure Setpoint 3psi amp Wake up Pres
12. to reconfigure system amp operate from keypad To enter the Programming mode at 17 01 VFD START STOP press the PAR button 17 press the double up arrow or he double down arrow until the ill allow VFD to Start and Stop Compressor o KEYPAD press the single down arrow We save the new value press the ENTER button To advance to the next parameter 17 06 EXT REF1 SELECT Press the single up arrow button reference to come from the KEYPAD To change from COMM MODULE o KEYPAD press the single down arrow This is only required if Constant Speed is desired from he VFD Keypad To save the new value press the ENTER button 25 1 R gt 115 0 PSI 17 START STOP REF 01 VFD START STOP COMM MODULE 1 R gt 115 0 PSI 17 START STOP REF 01 VFD START STOP COMM MODULE 1 R gt 115 0 PSI 17 START STOP REF 01 VFD START STOP COMM MODULE 1 R gt 115 0 PSI 17 START STOP REF 01 VFD START STOP KEYPAD 1 R gt 115 0 PSI 17 START STOP REF 01 VFD START STOP KEYPAD 1 R gt 115 0 PSI 17 START STOP REF 06 EXT REF1 SELECT COMM MODULE 1 R gt 115 0 PSI 17 START STOP REF 06 EXT REF1 SELECT ICOMM MODULE 1 R gt 115 0 PSI 17 START STOP REF 06 EXT REF1 SELECT KEYPAD 1 R gt 115 0 PSI 17 START STOP REF 06 EXT REF1 SELECT KEYPAD To return the display to the Actual Signal Display Mode press the ACT button To change from REMOTE to LOCAL Mode press the LOC REM button
13. 26 COMPRESSOR VFD STATUS j co Fan UFD Status 1 Press FAN VFD STATUS on menu FIG 25 amp n screen with fan data will appear speed RPM Pa an Torque tH Current SARI Dio Bus TA LO kUh x 16 Power ki Discharge Dil Temp F 3 FIG 27 FAN VFD STATUS Se Ka EEEN 4 7 Aliz Oil Tempi 34 59 Al24 Ext Press Output Test ing Compres 0or Runni na umne Pressi oO Fe GIS 3 E ta E Fan Motor Fault Remote Start Input IT oe Losa Far Runni ng Alarm or Foi Zei ero i I Va Ci LE FIG 28 I O STATUS COMPRESSOR STOPPED Input Air Fltr Block Hiah Air Temp Alia Oil Tempi Alza Ext Press Alza cs um i mo TE i E TOP CES E AFA TO or IC F Fa E Fan Motor Fault Surat e Remote Start Alarm ar rpiut Faul t Legg Laa IMPUT a le DO al Air Flitre Black Hiah Air Temp FIG 29 I O STATUS COMPRESSOR RUNNING Act ivate Outputs FIG 30 COMPRESSOR STATUS OUTPUT TESTING CAP320 1 Press I O STATUS key on screen FIG 25 to see input output data 2 Sceen displays oil temperature amp air pressure analog sensors output data digital inputs status Status of devices 3 Press Output Testing key to test solenoid valve fan amp optional external alarm FIG 30 Note output testing is only permitted in compressor stop mode 1 Screen displays input output data in compressor run mode Note
14. 30 2 E X30 3 Se X30 4 Es x30 5 CN X30 6 a X30 7 GND X30 8 aay 29 CASO GND X30 10 yr 26 Z822 RS 489 a Panel FAULT ae X20 Ag GREEN ER 1 V REF 10V POWER L g GND INPUT DESIGNATION gt er a DISCH JIL TEMP l POR MU OUTPUT DESIGNATION pr e GND ADI ADE 0 4 20m4 ce ORANGE 1 A 5 All a VW f ES p i BROWN 2 mA 5 y e EI a EXTERNAL PRESSURE om ys EI iva 3 N o CAO RED 4 10 lt 4 AD2 SUMP PRESSURE Ge H E kal 12 lt ZS a Dl Tas ii WHITE 6 L FEN ES YELLOW BLUE 8 8 U 7 L I Y FIG 49 WIRING DIARGRAM pg 2 30 CAP320 CAP320 o ca i rt li Sie e e e S EL GO i UT Y Y cy Pa 2 1 4 99 16 Y O E NW pa 4 _ 2 pg G IC JEN y ES E 45 e Sai Bl ci A FIG 50 INSTALLATION DRAWING VS50 50D OPEN UNIT AE A EE FIG 51 INSTALLATION DRAWING VS50 50D ENCLOSED UNIT 31 60 7 30 ke CAP320 AIR DISCHARGE CONNECTION FN WG DV Ree
15. CAP320 AUGUST 2004 REV A CURTIS TOLEDO OPERATOR S MANUAL SUPPLEMENT AF Series Compressors VS models with VFD N WARNING Personal injury and or equipment damage will result by failing to pay attention to the vital safety information and instructions in this manual Carefully read understand and retain all safety information and instructions before operating this compressor Curtis Toledo 1905 Kienlen Ave St Louis MO 63133 phone 314 383 1300 fax 314 381 1439 Email Curtiscomp aol com CAP320 FOREWORD The Curtis Toledo AF Series is a single stage helical rotary screw air compressor belt or direct driven by an electric motor The package includes the compressor air end main and fan motors VFD controls for operating the motors air intake system air oil separator and compressor instrumentation Curtis Toledo designs the AF Series compressors for indoor installation Standard control panel enclosure is NEMA 1 This manual is a supplement to basic rotary screw manual and written to aid the user in the daily operation of your compressor lt does not repeat installation safety and maintenance instruction and have a target to give comprehensive description of control system functions and operation We urge you to read and follow these instructions for the safe and economical operation of this unit Electricity and compressed air have the potential to cause severe personal injury and or property damage Bef
16. E Stop amp High Air Temperature inputs light on in normal conditions Compressor amp Fan are running Solenoid Valve energizing 1 Press Activate Outputs key to test serviceability of outputs RO1 fan RO2 external alarm RO3 solenoid valve activated relays will light up with 10sec time delay relays stay activated for 20sec artis Rotary Screu Compressor FIG 33 MAIN SCREEN STANDBY MODE CAP320 MAIN SCREEN MESSAGES 1 Compressor is running normally in Auto or Const mode Messages Drive Active Cooling Fan Active Compressor Loaded 2 Press STOP key if desired to stop compressor MAIN SCREEN MESSAGES 1 Compressor is blowing down amp will stop Messages Drive Active Cooling Fan Active Blowing Down Will Stop MAIN SCREEN MESSAGES 1 Compressor is in Standby sleep mode Standby Active message is flashing as a warning that compressor can restart any time activated by air demand Messages Drive Active Standby Active Compressor Unloaded CAP320 MAIN SCREEN MESSAGES 1 Compressor is in Lead Mode of Lead Lag control amp running normally When time is out compressor will switch to Lag Mode amp screen message will change to Lag Mode Lead Mode Messages Drive Active Cooling Fan Active Compressor Loaded Lead Lag Active Oil Temp Fs Lead Mode Loaded MAIN SCREEN MESSAGES 1 Compressor is in remote control amp can only
17. FIG 18 SETUP MODE CONSTANT CAP320 fiuto 7 Standby Mode Setup 1 Press Auto Auto Mode Setup FIG 17 18 to set auto mode parameters Auto Standby Mode Setup screen will appear FIG 19 2 Press digital display amp use numeric keypad to change parameters setting standby Delay Time Lid A Wak elle Pressure 165 6 dee e 1 Cutout Time Delay sec3 FIG 19 SETUP MODE AUTO STANDBY 1 Press UNITS TIME key on setup menu FIG 14 screen will appear 2 Press BAR or PSI C or F to switch between BAR units Changes will reflect on all digital displays amp dial meters on touch screen BAR 3 When C or F key is pressed the screen F FIG 20a with message Downloading Sag Parameters Please wait will appear 4 Press Adjust Time amp Date key to make fd iust Time amp Date appropriate adjustments Adjust Time amp Date screen will appear FIG 21 mg NIN rose FIG 20 SETUP UNITS Time Setup 1 Downloading parameters will take 12 15sec After completion the screen FIG 20 will appear FIG 20a SETUP UNITS Units 7 Time Se FIG 20b SETUP UNITS TEMPERATURE 18 13 21 87097 2064 FIG 21 SETUP TIME 8 DATE FIG 21a SETUP TIME 8 DATE djust Time Date CAP320 1 Press the Close key to return to screen FIG 20 1 Press the digits of item need to be adjusted amp numeric keypad will appear FIG 21a 2 Use
18. MID 01 DIL TEMP FDBK 24V GND DCDMI Dn A41 1 0 AND MOTOR CONTROL BOARD RMID 01 ACS800 S INPUT DESIGNATION E STOP ORANGE 9 x22 ee DI1 DI6 Nominal voltage 24VDC A ad 9 BROWN 0 gt DI Ze e y BLAC I 1 a 728 l E ke e i d E A ge REMOTE START STOP SERE 12 o Ss d s 11 GREE 3 3 911 p1s I SS d Dt ii MA LEAD LAG YELLOW 14 o Ia o 12 A D 3 RED A A 7 E 4V DI Max load AIR FILTER BLUCKED SWITCH DI7 Au START INTERLOCK TO E 13 PURPLE 16 Da TEMPERATURE SWITCH I 14 5 MOTOR THRERMAL PROTECTION T 16 Xe3 l A Max load 2 GND 250 mA OUTPUT DESIGNATION x25 DDI D03 250VAC 24 T ROI ENTE A 2 FAN VFD START 3 J BLUE xes ror 2 3 ALARM FAULT BROWN 19 X27 es OPTIONAL 1 As 2 DE Di 3 o V N ie BLACK 2 l xi a SOLENOID VALVE A41 1 0 AND MOTOR CONTROL BOARD fi RMID 01 ACS800 IN A 21 y L_ X34 a 1 GND tz 2 DC24V GREEN PA OPTION SLOTI sheet 20 A ES X32 PA OPTION SLOT2 sheet 21 Ree Ez BLACK 33 22 OPTION SLOTS sheet 22 gt o N L X30 1 END X
19. RR v D3 4 FUR SERVICE NEI 54 36 OR SERVIC i c o AIR DISCHARGE CONNECTION d 4 2 NPT al ki i o 32 1 4 o SA 1 A y Ff Li Pe 32 a 34 bi 36 108 36 FOR SERVICE FOR SERVICE FIG 52 INSTALLATION DRAWING VS75 8 VS100 OPEN UNIT 14 DI E gt 84 PA 3 108 Ns FIG 53 INSTALLATION DRAWING VS75 amp VS100 ENCLOSED UNIT 32 3x6 N FORKLI SLUTS ds FOR SERVICE CAP320 40 3 4 f FIG 54 INSTALLATION DRAWING VS125 150 OPEN UNIT ua I i l AIR U DISCHARG La ANANIN ATIA Y 9 J CONNECTION A KI 2NPT 5 6 MAX gt gt L 7 KE a K 82 84 56 SERVICE OR SERVICE FIG 55 INSTALLATION DRAWING VS125 150 ENCLOSED UNIT 33
20. each digital display amp change value by using numeric keypad 2 When Motor ID Required flashing message will appear press Run Motor ID key to save new motor data on drive When Motor ID is saved the Motor ID Complete message will appear 3 Press Motor Rotation Check key to check the motors rotation only if motors have been changed Rotation Check Active message will appear amp motors will rotate slowly for 10sec 4 Press Back key to return to screen FIG 37 Cooling Fan Motor Data HMominal Freq de KAN FIG 40 COOLING FAN MOTOR NAMEPLATE DATA Cooling Fan Setup An Fan Temp ul etpoint iF FIG 41 COOLING FAN SETUP TEMPERATURE SET 21 CAP320 1 Press Cooling Fan Motor Data kev to get screen FIG 40 2 Press Cooling Fan Temp Setpoint kev get screen FIG 41 3 Press Back to return to screen FIG 37 d Press Drive Parameter Download key the screen FIG 42 with message Downloading Parameters Please wait will appear At completion the screen FIG 43 with message Parameter Download Complete along with Close key will appear to Note change the nameplate data 4 download motor parameters only if motor has been changed 1 Enter motor nameplate data pressing each digital display amp change value by using numeric keypad 2 Press Back to return to screen FIG 39 press Drive Parameter Download key on screen FIG 39 to save fan motor parameters to fan drive
21. essage at 0 hrs 4000 hrs 4000 hrs TS Fig 3 6 Warning message at 0 hrs Oil 8000hrs 12000 hrs TS Fig 3 6 Warning message at 0 hrs Panel filter 2000 hrs 2000 hrs TS Fig 3 6 Warning message at 0 hrs TS Fig 3 6 dell More SE 22 37 45 TI TS Fig 3 6 CAP320 1 3 3 Energy savings Table 3 Parameter Name Default Min Max Displav Remarks 0 99999 Energy savings kWhx100 0 kWhX100 kWhX100 TS Fig 26 Dollar savings 0 0 00 999999 TSFig26 Load motor Amp 95 NA 150 TSFig22 Unload motor Amp 30 NA 150 TSFig22 Motor load time TS Fig 22 TI 1 3 4 Compressor type data Table 4 Parameter Name Default Min Max Comp type Blowdown time Shutdown pressure 115psi 7 9bar 0 115psi 7 9bar Load pressure 105psi 7 2bar 85psi 5 9bar 120psi 8 3bar_ 5 Unload pressure 125psi 8 6bar 95psi 6 6bar 130psi 9 0bar Sr 01 01 O1 Shutdown pressure 140psi 9 6bar 0 140psi 96bar 5 Blowdown time 5sec See 120sec 9 Stop delay time 30sec 10sec 240sec 9 o Load pressure 130psi 9 0bar 110psi 7 6bar _145psi 10 0bar 9 Unload pressure 150psi 10 3bar 120psi 8 3bar 155psi 10 7bar 9 Shutdown pressure 165psi 11 4bar 0 165psi ti4bar 9 Shutdown pressure 190psi 13 1bar 190psi 13 tbar 13 Notes 1 For pressure range 175 200psi consult factory 2 Compressor type set by factory or field service personnel CAP320 1 4 Param
22. eter definitions 8 descriptions 1 4 1 Basic parameters EXTERNAL PRESSURE is compressor discharge pressure Measured by pressure transducer providing analog 4 20mA pressure feedback signal to drive PLC TS FIG 1 SUMP PRESSURE separator pressure Measured by pressure transducer providing analog 4 20mA pressure feedback signal to PLC TS FIG 1 DP PRESSURE is differential pressure between wet side of sump amp discharge air line Calculated as Sump Pressure External Pressure UNLOAD PRESSURE is External Pressure level that determines when the compressor starts working offload TS FIG 15 The unloading of the sump will occur if Unload Level is met for period of time defined by CUTOUT DELAY TIME or External Pressure will reach Unload Level 5psi Unload Pressure level is adjustable LOAD PRESSURE is External Pressure level that determines when the compressor starts working load TS FIG 15 Load Pressure level is adjustable OPERATING PRESSURE is the pressure setpoint used to regulate the speed of the compressor based on External Pressure feedback signal TS FIG 19 Operating Pressure level is adjustable WAKE UP PESSURE is External Pressure level that determines when the compressor being in Standby Mode will automatically re enter the running loading condition TS FIG 19 Wake up Pressure level is adjustable SHUTDOWN PRESSURE is External Pressure or Sump Pressure maximum level to blow down and stop compress
23. or if this pressure level will be exceeded TS FIG 45 Alarm message will be issued Shutdown Pressure is adjustable by factory personnel only OIL TEMPERATURE is the air end discharge oil temperature Measured by temperature sensor providing analog feedback signal to drive PLC TS FIG 1 SHUTDOWN TEMPERATURE is maximum oil temperature to blow down and stop compressor if this temperature level will be exceeded TS FIG 37 45 Alarm message will be issued Warning message will be issued when the temperature exceeds Shutdown Temp 10 F 5 56 C Shutdown Temperature is adjustable by factory and field service personnel only AUTO RESTART TIME is adjustable time delay the compressor will wait on a power loss before automatically restarting TS FIG 15 STOP DELAY TIME is adjustable time delay It defines the interval of time the compressor will continue to run at the last speed when the drive is issued a stop command TS FIG 15 BLOWDOWN TIME is adjustable interval of time after the compressor has been issued a stop command that the drive is not allowed to restart TS FIG 15 CUTOUT DELAY TIME is adjustable time delay issued when External Pressure reaches the Unload Pressure level compressor running in AUTO mode to allow PLC to respond to a slight pressure overshoot TS FIG 19 This will only apply at initial start or if drastic pressure changes have occurred in the system STANDBY DELAY TIME is adjustable delay time
24. ore installing wiring starting operating or making any adjustments identify the components of the air compressor using basic manual and this supplement as a guide Qualified personnel adequately equipped with the proper tools should perform maintenance Follow the maintenance schedules as outlined in the manual to insure problem free operation after initial start up The operator should use common sense and good working practices while operating and maintaining this unit CAP320 TABLE OF CONTENTS CONTROL SYSTEM 8 SETTINGS INTRODUCTION SOFTWARE 4 2 Ss PARAMETER TABLES pci toata ae ea poeti oaia EEN 3 1 BASIC PARAMETERS AND SETTINGS eee aaa Ser SERVICE AND STATISTIC Sirva A ASA A da 3 9 ENERGY SAVINGS i soi ste ana 3 4 COMPRESSOR TYPE DATA 4 PARAMETER DEFINITIONS AND DESCRIPTIONS 4 1 BASIC PARAMETERS 4 2 ENERGY SAVINGS TOUCH SCREEN OVERVIEW 8 ORERATION eee nea DRIVE KEYPAD OPERATION psi ieri dag boreal hadet de ag ti na br oaia ai 25 MAINTANENCE 27 DRAWINGS 28 NN 0002200 0yYN y CAP 320 1 CONTROL SYSTEM AND SETTINGS 1 1 Introduction AF rotary screw compressor series with variable frequency AC drives VFD is a new generation of energy saving Curtis compressors AF is compact package including control panel with compressor fan VFD touch screen and other electrical components pressure and temperature sensors air filter switch Compressor VFD ACS800 AC drive ABB Inc utilizes Direct Torque
25. start remotely START key on screen replaced by Start From Remote Site message Messages Drive Stopped Compressor Unloaded Start From Remote Site Start From Remote Site FIG 35 MAIN SCREEN REMOTE OPERATION Security Logon H Field Service Setup FIG 36 FIELD SERVICE SETUP ACCESS Fan Motor shutdown Compressor Motor Conf igure Cooling Fan Motor Conf igure Hominal Current L AMPS Morni mal Voltage Co Soy Ham i ral Freq Hz HP Temp LFi Motor ID Motor Rotat ton Check FIG 38 COMPRESSOR MOTOR NAMEPLATE DATA 20 CAP320 FOR FIELD SERVICE 1 On Security Logon screen FIG 24 press the 0 to get numeric keypad amp enter 4 digit password consult factory for password amp Field Service Setup key will appear 2 Press this key to get Field Service Access Setup screen FIG 37 1 Press digital display Compressor type Fan motor HP Shutdown Temp amp use numeric keypad to change parameters setting If wrong compressor type is entered the flashing message Invalid Comp Type will appear 2 Run Hrs amp Load Hrs digital displays are for information only 3 Press Compressor Motor Configure key to get Compressor Motor Nameplate Data screen FIG 38 4 Press Cooling Fan Motor Configure key to get Cooling Fan Setup screen FIG 39 Note change the nameplate data run motor ID only if motor data has been changed 1 Enter motor nameplate data pressing
26. sure level will automatically set to value of Load Pressure Lead Lag pressure value default 5psi Both parameters are not adjustable by user EXTERNAL ALARM is optional device 110VAC 2A wired to terminals 19 amp N Ref Wiring diagram FIG 49 CAP320 e OIL TEMPERATURE SETPOINT is used to set optimum oil temperature for compressor normal operation set TS FIG 41 displayed TS FIG 27 Oil Temperature set by factory or field service personnel only Fan motor will start when oil temperature will reach the setpoint and stop at 160 71 1 C Fan VFD regulates fan speed holding the oil temperature at setpoint 1 4 2 Energy savings Energv savings data calculated bv PLC based on comparison of energv consumption bv compressor operating from VFD in a Closed Loop Pressure control system and Across the Line starter with continuous run at full speed while loading unloading the compressor User should set the following parameters e LOAD MOTOR AMP This is percentage of the Main Motor Nominal Current FLA that would be required by Across the Line motor running compressor under load e UNLOAD MOTOR AMP This is percentage of the Main Motor Nominal Current FLA that would be required by Across the Line motor running compressor when unloaded e MOTOR LOAD TIME This is percentage of common cycle of the machine load unload when compressor runs in a loaded condition CAP320 2 TOUCH SCREEN OVERVIEW 8 OPERATION
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