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FS-ELLIOTT LLC 5710 Mellon Road, Export, PA 15632-8948 USA

Voice: 724-387-3200 Fax 724-387-3270


Website http://www.fs-elliott.com/

Pre-Start Technical Manual
P500 with Regulus Control Panel


P-500
lws 8/29/2007 i





LIMITATIONS, WARRANTY AND SAFETY


LIMITATION

It is to be noted that none of the drawings or printed material contained in this
handbook in any way adds to, detracts from, voids or alters any of the conditions of the
contract. Such drawings and/or printed materials are for descriptive purposes only and
are not to be construed as determining the scope of supply or the performance of the
equipment. Please consult your contract to determine these particulars.

Such drawings shall be deemed to be and remain FS-Elliott's proprietary property and
reproduction, distribution or disclosure of any part of the contents is expressly
forbidden without written consent.

WARRANTY

SELLER warrants against defects on all GOODS for a period of twelve (12) months
from date of startup or use or eighteen (18) months from the date of shipment,
whichever comes first and SELLER warrants against defects in workmanship on all
SERVICES performed by SELLER for a period of ninety (90) days from date of
completion of such SERVICES, provided that BUYER notifies SELLER in writing of
such defects in GOODS or SERVICES within the appropriate warranty period.
SELLERS obligation to repair or replace defective GOODS or re-perform defective
SERVICES is SELLERS sole liability and BUYERS exclusive remedy arising under
this or any warranty claim. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES
OF MERCHANABILITY AND FITNESS FOR A PARTICULAR PURPOSE. SELLER
shall not be responsible for labor or other charges resulting from removal or
reinstallation of defective GOODS, charges for transportation, handling, shipping, taxes,
duties, insurance or travel. No allowance will be made for repairs or alterations made by
others without SELLERS written consent of approval. If repairs or alterations are
attempted without SELLERS consent or approval, the warranty is null and void.
SELLER assumes no responsibility for damages caused by improper installation or by
operation in violation of its rated operating condition, or by improper handling or
maintenance. None of the GOODS furnished by SELLER shall be deemed defective by
reason of failure to resist the action of erosive or corrosive gases or liquids or the
deposition of foreign materials.

STANDARD WARRANTY EXTENSIONS

When FS-Elliott Corona Turbo Blue or Corona Turbo Clear lubricants are utilized
in combination with an oil testing program and/or distributor-sponsored maintenance
programs as outlined in our extended warranty program, the actual warranty period for
the air end component can be extended beyond the periods stated above.

The foregoing are FS-Elliott's standard terms and conditions of warranty. Please
consult your contract for any clarifications, alterations and/or modifications thereto.
lws 8/29/2007

ii

SAFETY

It is assumed that your safety department will have established a program of safety
based upon a thorough analysis of industrial hazards. Before installing and operating
or performing maintenance on the equipment described in this instruction book, it is
suggested that you again review this program to be certain that it covers the hazards
arising from high speed rotating machinery.

It is also important that due consideration be given to those hazards which arise from
the presence of electrical power, hot oil, high pressure and temperature, steam, toxic
gases and flammable liquids and gases. Proper installation and care of protective
guards, shutdown devices and over-pressure protection should also be considered
essential parts of any safety program.

Also essential are special precautionary measures to prevent the possibility of applying
power to the machine at any time when maintenance work is in progress. The
prevention of rotation due to reverse flow in dynamic machinery should not be
overlooked.

In general, you should be guided by all basic safety rules associated with the
equipment and the process.

-WARNING-
THE FS-ELLIOTT COMPANY CANNOT ASSUME
ANY RESPONSIBILITY FOR DAMAGES OR
PERSONAL INJURY RESULTING FROM
OPERATION OF THIS EQUIPMENT WITH
SAFETY AND/OR SHUTDOWN DEVICES BEING
ISOLATED, DISABLED OR BYPASSED.

-WARNING-
IT IS ESSENTIAL THAT UNITS EQUIPPED WITH
A CURRENT TRANSFORMER HAVE
EXPERIENCED PERSONNEL PERFORM ITS
INSTALLATION /TESTING. CURRENT
TRANSFORMERS CAN DEVELOP A LETHAL
VOLTAGE AND SELF DESTRUCT IF THE
SECONDARY IS OPEN WHEN PRIMARY
CURRENT IS PRESENT.

_______________________________________________________________________________

COPYRIGHT
The information contained in this technical manual is the property of FS-Elliott Company LLC and is
furnished for use by the assigned recipient only. Reproduction, disclosure or distribution of any part of the
contents of this manual is expressly forbidden without written consent of FS- Elliott Company LLC.
FS- ELLIOTT COMPANY, LLC 2007

FS- Elliott Company Phone: 724-387-3200
5710 Mellon Road FAX: 724-387-3270
Export, PA 15632-8948 USA www.fs-elliott.com

ISO 9001:2000 CERTIFIED


PRINTED IN THE U.S.A.


Regulus
TM
End User Programming
and Software Authorization
Form FSE-4000 (10/31/05)

Subject to the terms and conditions of this Agreement, FS-Elliott Co., LLC (FSE) hereby grants
the end-user of FSE products and services (Licensee), a non-exclusive license to use the
software installed in FSEs Regulus Control Panels (Software).

Any other use of the Software is not authorized and is strictly forbidden. Notwithstanding the
above, Licensees third-party contractors or consultants shall be permitted to use the Software (a)
solely for the benefit of Licensee; (b) only according to the terms of this Agreement; and (c) with
technical support to be coordinated through Licensee. Licensee shall at all times be responsible for
compliance by its contractors and consultants.

Licensee agrees not to reproduce, deactivate or bypass the security devices for use of the software
in other equipment. Licensee agrees to preserve and respect all copyright, proprietary rights and
confidentiality notices and other restricted property rights notices on the Software. Licensee agrees
not to disassemble or reverse-engineer the software.

This Software is subject to all applicable export laws in accordance with U.S. Export Administration
Regulations and Licensee hereby agrees that neither the Software, nor the equipment that it is
installed in, are intended to be shipped, either directly or indirectly to any embargoed countries nor
used for or in support of any prohibited activities.

FSE warrants the Software will substantially operate according to specifications and is subject to
FSEs warranty for the control panels. Unauthorized modifications to the Programming and/or
Software will void the warranty.

FSE may terminate this Agreement (i) upon thirty (30) days prior notice, provided however, that
Licensee has not remedied its failure to FSEs satisfaction within the thirty (30) day period; (ii) files
a petition in bankruptcy or is adjudged bankrupt; (iii) becomes insolvent; and, (iv) makes an
assignment for the benefit of creditors.

This Agreement represents the complete and exclusive statement of the agreements concerning
the license between the parties, and may be modified only in writing signed by both parties. Should
any provisions of this Agreement be determined to be void, invalid or otherwise unenforceable
This Agreement shall be governed by and construed under the laws of the Commonwealth of
Pennsylvania.

FS-Elliott Co., LLC
5710 Mellon Road
Export, Pa. USA 15632-8948
Phone (724) 387-3200
Fax (724) 387-3270
www.fs-elliott.com



ISO 9001:2000 CERTIFIED PRINTED IN THE U.S.A.
APPENDIX B
SALES AND SERVICE LOCATIONS
10/02/2008
FS-Elliott Company has sales and service facilities throughout the world. Whatever your application or
service need, an experienced FS-Elliott Field Engineer or Sales Representative will assist you anytime or
anywhere. For the nearest Authorized Sales or Service Local Distributor or Representative, contact any of
the FS-Elliott offices below or visit our web site at www.fs-elliott.com

HEADQUARTERS FS-Elliott Company, LLC
5710 Mellon Road
Export, Pennsylvania 15632-8948
United States of America
Phone: 724-387-3200 Fax: 724-387-3270

NORTHEASTERN USA FS-Elliott Company, LLC
EASTERN CANADA 6013 Enterprise Drive
Export, Pennsylvania 15632
United States of America
Phone: 724-387-3200 Fax: 724-387-3201

SOUTHEASTERN USA FS-Elliott Company, LLC
115 Green Turtle Lane
Carolina Beach, North Carolina 28428
United States of America
Phone: 910-458-5088 Fax: 910-458-0224

SOUTHWESTERN USA, FS-Elliott Company, LLC
LATIN, SOUTH AMERICA 4800 Sugar Grove Boulevard, Suite 340
MEXICO Stafford, Texas 77477
United States of America
Phone: 832-532-7130 Fax: 832-532-7138

WESTERN USA FS-Elliott Company, LLC
WESTERN CANADA 20955 Pathfinder Road
ASIA / PACIFIC Suite #215
Diamond Bar, CA USA 91765
United States of America
Phone: 909 839 1580 Fax: 909 594 3281

EUROPE, MIDDLE EAST FS-Elliott Company, LLC
& AFRICA 3.02 Network House
Basing View
Basingstoke, Hampshire RG21 4HG
United Kingdom
Phone: +44-1256-341-890 Fax: +44-1256-358-259

SOUTHEAST ASIA FS-Elliott Company, LLC
No. 3 Pandan Valley
#03-305
Singapore 597627
Singapore
Phone: +65-6467-8980 Fax: +65-6463-3711

CHINA FS-Elliott (Shanghai) Machinery Co., Ltd
3F-A,B No. 686 Gubei Road
Shanghai 200336
Peoples Republic of China
Phone: +86-21-6270-4866 Fax: +86-21-6270-4868
2009
Customer Training
for FS-Elliotts Plant Air Packages
Centrifugal Compressors for Oil Free Air
Introduction to FS-Elliott
FS-Elliotts oil-free air compressors have acquired a prestigious heritage
since being introduced to the marketplace over half a century ago. These
compressors are installed around the globe in facilities that produce a vast
array of products that impact all facets of todays economy. Our compressors
have been continuously updated over the years, and today our portfolio
includes the long-established PAP Plus

and Polaris

product lines. The PAP


Plus

units target applications that require customized congurations and


have special customer needs. The Polaris

units are designed for traditional


industrial applications. Every FS-Elliott compressor is carefully crafted and
undergoes the same rigorous execution process including product design,
manufacture, and inspections governed by our ISO 9001:2000 Certied Quality
Management System. Our product line ranges from 150 to 6,000 hp (110 to
4470 kW) and covers 500 to 25,000 ICFM (850 to 42475 m
3
/h). From the smallest to
the largest compressor models, the design philosophy is simple and consistent:
we combine unyielding reliability with leading-edge technology to ensure that
your vital operations will not be interrupted or compromised.
FS-Elliotts compressors are the best choice for efcient and reliable
compressed air. We are aware that if your air source is down for even a single
day, it can result in an unplanned facility outage. That is why we design and
build our compressors for long-term reliability with features you can count on.
Our oil-free air compressors truly deliver genuine engineered air to every
application. ALL compressors employ features such as:
Easy accessibility for low-cost maintenance.
Fewer rotating and stationary parts for high reliability
Unitized construction that simplifes installation.
Standardized designs that accommodate easy uprating.
Noise levels that meet or exceed OSHA compliance levels.
FS-Elliott recently invested millions of dollars in purchasing new
facilities, machine tools, and relocating operations to Export,
Pennsylvania. The site includes two modern facilities with more
than 200,000 ft
2
(18580 m
2
) of manufacturing and ofce space
situated on over 30 acres (12.2 hectares) of land. A new state-
of-the-art test facility was commissioned in September 2006.
Our worldwide network of local certied technicians provides
professional service twenty-four hours a day, seven days
a week, three hundred sixty ve days a year. You can rely
on FS-Elliotts service personnel to answer your questions
and provide solutions to your compressor difculties.
FS-Elliott can provide any level of service required including:
Installation and start-up including total turnkey service
Maintenance programs including free lubricant sampling and
analysis
Genuine FS-Elliott spare parts to maintain optimum reliability
Rerates and upgrades that leverage initial investments
Repairs performed locally and on a timely basis
Training for you to become knowledgeable partners with us
FS-Elliott extends an invitation to attend our 2009 Customer
Training program and tour our facilities in Export, Pennsylvania
and, to witness rst-hand our customer-focused organization
and state-of-the-art facilities.
Thousands of FS-Elliott Plant Air
Package (PAP PLUS

) and Polaris


compressors have been installed and
operate worldwide. The current series
of compressors incorporates the latest
technology to insure high efficiency,
economy and reliability. FS-Elliott
training courses give students a thorough
knowledge of PAP Plus

compressor
components, lube oil components, and
its operation.
The FS-Elliott control system provides
optimum performance, reliability and
convenience for the PAP PLUS

compres-
sors. Students of the FS-Elliott customer
training courses learn about the control
components, operation, and trouble-
shooting.
For additional details on FS-Elliotts products, services and training programs go to
www.fs-elliott.com to find the contact information for the distributor nearest to you.
Training Registration
Contact one of the individuals below for registration or complete
and mail the form below:
Company
Contact

Phone and Fax
Billing Address

City, State Zip
Attendees Names
Method of Payment
Check/Money Order/Credit Card/Purchase Order
Claudia Umak
cumak@fs-elliott.com
724-387-3294
Mike Lantzy
mlantzy@fs-elliott.com
724-387-3215
FS-Elliott Co., LLC
6013 Enterprise Drive
Export, PA 15632-8969
U.S.A.
www.fs-elliott.com
WHO SHOULD ATTEND
This course is designed for operators, maintenance personnel,
instrumentation technicians, and supervisory personnel.
OBJECTIVES
Upon successful completion of this course, the student will be
able to:
Identify all of the major compressor components
Explain the compressor component functions
Set proper bearings clearances
Operate and maintain a compressor
Start and stop the unit
Calibrate the controls
Troubleshoot various conditions
COURSE OVERVIEW
Air System
Lubrication System
Control Theory and Hardware
WORKSHOPS
Setting Clearances
Panel Operation
Panel Troubleshooting
COST
The cost is $1000 (US) per person. This includes the course
tuition, training materials, a manual, daily refreshments, lunches,
dinner for one evening, and an attendance certicate.
Any company that registers two students will receive a 10%
discount for each additional student.
Travel and living expenses are not covered by FS-Elliott. FS-Elliott
reserves the right to cancel a training session due to insufcient
attendance. We recommend that you book fully refundable
airline tickets or wait until the program is conrmed before
making your reservations.
COURSE INFORMATION
Classes are held at the FS-Elliott Service Center on
Enterprise Drive in Export, Pennsylvania, from 8:30 AM to 4:00
PM daily for three days.
Course Dates for 2009
April 21-23
October 20-22
ACCOMMODATIONS
For convenience, make hotel reservations at the Holiday Inn
Express in Delmont, Pennsylvania, which is a short drive from
the FS-Elliott Service Center. To make a reservation call (724)
468-1050 or Fax: (724) 468-5030. Be sure to ask for the FS-Elliott
corporate discount when making reservations.
FS-Elliotts new Service Center in Export, Pennsylvania, houses the
corporate training classrooms.
Chapter 1
General Information
P500.ch01.07/02/2007 1-1

INTRODUCTION

This technical manual supplies information for the installation, operation, and
maintenance for your FS-Elliott equipment. To avoid operational and maintenance
difficulties, special attention should be given to the precautionary instructions
emphasized throughout the manual.

Table of Contents contains Customers Order Information, Equipment Data and
Limitations, Warranty and Safety.

Chapter 1 - General Information provides a description of the equipment and
procedures for unpacking, handling and storage.

Chapter 2 - Installation discusses the basic foundation requirements along with the
alignment procedures, piping recommendations and other installation details.

Chapter 3 - Operation provides equipment guidelines for start-up and shutdown
procedures including recommended safety precautions to observe during operation.

Chapter 4 - Maintenance supplies a recommended routine maintenance schedule
along with disassembly, assembly and adjustment procedures.

Chapter 5 - Lubrication describes the lubrication system, the oil requirements and
gives consideration to the care of the lubricating oil.

Chapter 6 - Control System furnishes information required for operating, adjusting
and maintaining the control system.

Chapter 7 - Troubleshooting provides probable causes of problems and the
necessary corrective actions.

Chapter 8 Accessories - contains instructions and/or data and drawings applicable
to various accessory components provided with the equipment.

Chapter 9 Service/Parts/Sales provides the Normal Maintenance Parts List,
information on how to order parts and where to obtain service assistance and training
for operators and maintenance personnel.

Chapter 10 Technical Drawings - contains specific drawings for your equipment.
The drawing numbers may have a suffix number, or group number identifying the
applicable assembly on the drawing. Be sure to use the suffix listed when making
reference to a drawing.

Chapter 1
General Information
1-2 P500.ch01.07/02/2007


FACTORY TESTS

Polaris Compressors are completely assembled and tested before shipment. During
tests the control system, protective devices and the electrical, pneumatic and mechanical
systems are checked for satisfactory operation.

Setpoints
The setpoints for the air compressor units are entered at the FS-Elliott factory. These
setpoints are shown on the Control Panel Configuration Sheet located in the Equipment
Data section of this manual. The control modes, transmitters and options are also shown
on Control Panel Configuration Sheet. Any control mode, start/stop mode, or setpoint that
is not shown on the Control Panel Configuration Sheet is optional and is not enabled.
Also, "Option Not Enabled" indicates that the electronic control panel is not programmed
for these features. Factory reprogramming is required if these features are desired.

Note
The Control Panel Configuration Sheet does not
indicate FS-Elliott Company's scope of supply.
Transmitters, pushbuttons, and pressure switches may
be customer supplied or FS-Elliott Company supplied.
Refer to the purchase order.

SHIPMENT

Polaris Compressors are mounted on skids and covered with crating before shipment.
Although the crating is constructed to commercial standards, it does not protect against
rough handling. Rust preventative is applied to exterior unpainted machined surfaces to
prevent corrosion during shipment and storage. Compressors intended for export
shipment are normally boxed in waterproof containers having extra bracing.

Note
Due to shipping restrictions, some items may be
packaged separately. Refer to packing list enclosed
with your shipment.


TABLE 1-1 SHIPPING PREPARATIONS
DURATION (MONTHS)

______________________________________________________________

CLASS INDOOR STORAGE OUTDOOR STORAGE
______________________________________________________________

A 3 NOT ADVISED
______________________________________________________________

C 6 3
______________________________________________________________

Chapter 1
General Information
P500.ch01.07/02/2007 1-3


STORAGE

Store the compressor indoors whenever possible. Keep the storage area clean, dry and
free from temperature extremes. A rust preventative is applied to the compressor before
shipment. The protective effectiveness of the rust preventative is significantly reduced by
conditions encountered during outdoor storage. Storing the compressor outdoors often
subjects it to extreme temperature changes, excessive moisture and, in some instances,
salt laden air. Precautions must be taken to avoid these extreme conditions during
storage.

There are two classes of shipping preparations used to preserve and protect the
compressor during storage. Table l-l shows the maximum storage time for each class.
The class used on your compressor is shown on the General Data page found in the
Equipment Data section of this manual.

UNPACKING

Remove the crating and account for all items on the packing list. Make sure there are no
missing or damaged parts. Handle all parts carefully. If the equipment was damaged
during shipment, contact the carrier and file a damage claim immediately. If items are
missing, contact the nearest FS-Elliott Company.

LIFTING AND HANDLING

Lifting and handling of the Polaris compressor must be planned around facilities
available at the installation site.

The box beam supports of the unit can be used to lift the unit by a fork truck. The fork
truck should lift the compressor from the control panel side. This will keep the center of
gravity of the compressor closer to the forklift. Refer to Figure 1-1 for details.

In the event that a fork truck is not available or cannot be used, the unit may be lifted with
an overhead crane by a professional rigger. The lifting points are the ends of the lifting
bars placed through each box beam. Lifting bars are not supplied with the unit and are the
responsibility of the owner or rigger.


-WARNING-
SINCE THE LIFT POINTS ARE BELOW THE
CENTER OF GRAVITY OF THE COMPRESSOR
ASSEMBLY, THE LIFT IS INHERENTLY UNSTABLE
AND IS PRONE TO THE DANGER OF FLIPPING.
THEREFORE, FS-ELLIOTT DOES NOT
RECOMMEND LIFTING THE COMPRESSOR
ASSEMBLY IN THIS MANNER UNLESS DONE BY
AN EXPERIENCED AND QUALIFIED RIGGING
PROFESSIONAL




Chapter 1
General Information
1-4 P500.ch01.07/02/2007

-WARNING-
DO NOT LIFT THE UNIT BY LIFTING EYES OR
SIMILAR PROVISIONS PROVIDED ON VARIOUS
PACKAGE COMPONENTS. THESE ARE ONLY
SUITABLE FOR LIFTING THE INDIVIDUAL
COMPONENTS.

All boxed units have lifting points printed at the appropriate locations. Select crane
capacities and lifting accessories accordingly.

Actual weights of the "as shipped" compressor are shown on the shipping documents.
Estimated weights of the compressor without skid and/or box is shown on the compressor
outline drawing found in Chapter 10, Technical Drawings. Driver weights are shown on
the certified driver outline drawing located in Chapter 8, Accessories.

FIELD SERVICE ASSISTANCE

FS-Elliott Company provides a one source, full service operation that meets all of your
service needs. Field Service Representatives are available to oversee the installation and
start-up or any phase of maintenance of FS-Elliott equipment. Also, Field Service
Engineers are available to conduct Performance Analysis and other related equipment
evaluations. For a location of an FS-Elliott Service office near you, refer to the Sales and
Service Offices found in Chapter 9 (Service/Parts/Sales) of this manual.


FACTORY REPAIR

Major repair and rebuilding of FS-Elliott equipment can be done in our factory, or
authorized repair shops around the world. Contact the nearest FS-Elliott Company for
details.

Chapter 1
General Information
P500.ch01.07/02/2007 1-5



FIGURE 1-1
SUGGESTED FORKLIFT ARRANGEMENT


A FORKLIFT CAN BE USED BY INSERTING THE FORKS INTO THE BOXBEAMS UNDER THE
BASEPLATE AS SHOWN IN FIGURE 1-1. DO NOT ATTEMPT TO LIFT THE UNIT WITH FORKS
IN ANY OTHER ORIENTATION. A SAFETY HAZARD OR UNIT DAMAGE MAY OTHERWISE
RESULT.

Caution
Care should be taken so that the forklift does not
damage the compressor.

Chapter 1
General Information
1-6 P500.ch01.07/02/2007



POLARIS COMPRESSOR GENERAL DESCRIPTION

The Polaris Model DA3 is a three stage centrifugal compressor. The DA2 is a 2 stage
centrifugal compressor and the SA1 is a single stage centrifugal compressor. The first
stage impeller on all three models is mounted on the low speed pinion; the second and
third stage impellers, if applicable, are mounted at opposite ends of the high-speed pinion.
The impellers are housed in scroll type casings.

Both pinions are driven by one bullgear. The gear and pinions are helix design and are
housed in a horizontally split gear case. The pinions are supported radially by tilting pad
journal bearings. The gear is supported radially by sleeve type bearings. Machined
shoulders and collars on the pinion and gear shafts bear against vertical babbitted
surfaces on the journal bearing retainers, absorbing axial rotor thrust.

Horizontally-split carbon seal assemblies prevent air leakage along the pinion shafts into
the gear case and oil leakage along the pinion shafts from the gear case. A double lip,
radial-type oil seal prevents oil leakage from the gear case along the gear shaft.

The Polaris base supports the compressor components. The driver end of the base
forms a lubricating oil reservoir. The compressor end of the base houses the first and if
applicable, second stage intercoolers. The control panel and lubrication system
components are located at the sides of the base.

Lubrication System
The lubrication system consists of a main oil pump, auxiliary oil pump (located in the oil
reservoir), oil filter, oil cooler, oil pressure control valve, pressure and temperature
indicating devices, a reservoir, thermostatic mixing valve, oil reservoir heater and
necessary piping, fittings and valves. See Chapter 5, Lubrication System, for details.

Cooling Water
Cooling water maintains air and lubrication oil temperatures within design limits. The air
coolers are shell and finned tube type. Oil coolers are shell and finned tube type; cooling
water passes through the tubes and cooled medium through the shell and around the
tubes.

Motor Starter
The motor starter is an optional ship loose device that can be provided with the
compressor package.

Auxiliary Oil Pump Starter Panel
Located below the control cabinet, the Auxiliary Oil Pump Starter Panel contains the AOP
contactor and overload protection, and transformer for 110 VAC supply to various
components on the compressor.

Chapter 1
General Information
P500.ch01.07/02/2007 1-7


Control Cabinet
The control cabinet mounted on the side of the compressor base contains the electronic
circuitry that controls the compressor's operation.

Control System
The control system regulates the airflow through the compressor by positioning the air
inlet control valve and the discharge air unloading valve. The controls also unload the
compressor when surge occurs. The control system performs the following functions:

1. Starts/stops the air compressor unit

2. Motor amperage control or inlet air density control

3. Discharge pressure control

4. Suction throttling control

5. Intermittent mode control

6. Auto dual mode control

7. Auto start stop control

8. Surge protection

9. Alarm and trip indication

10. Data storage


Chapter 2
Installation
P500.chap02.07/02/2007 2-1



INTRODUCTION


Proper installation will contribute to trouble free operation with minimum maintenance. This
section includes detailed procedures for ensuring a successful installation. Drawings issued
by FS-Elliott Company provide important installation details. Study these drawings closely
and refer to them for mounting dimensions, electrical and piping connections, required
clearances for maintenance purposes, etc. The instructions in this section, along with the
information shown on the drawings, should be thoroughly understood before installing the
Polaris Compressor. Technical drawings relating to the equipment can be found in
Chapter 10, Technical Drawings. Technical drawings related to accessory items used on
the equipment can be found in Chapter 8, Accessories.

Successful installation requires specialized knowledge and skills. For this reason it is
recommended that an FS-Elliott Company Service Representative be retained to supervise
the installation and initial startup. Installation site conditions vary greatly and may make it
necessary to deviate from the procedures in this manual. Do not deviate without a service
representative who can suggest alternate procedures to better suit specific field or service
conditions and thereby provide the best possible installation. Regardless of the procedure,
quality materials and workmanship are an absolute necessity for a successful installation.

Caution
Welding on the compressor package is normally not
required for installation. However, if electric welding
is required alternating current should be used. Use
of direct current may result in residual magnetism
that could cause damage such as frosting of the
bearings or may affect electrical runout.
Additionally when welding, the electrical ground
should be positioned as close as possible to the
weld area. Minimize welding in the vicinity of the
control panel on compressors equipped with digital
type control systems.

FOUNDATION

The principle function of the foundation is to provide a permanently rigid, non-warping
support for the compressor. Proper fulfillment will, (1) hold equipment in proper alignment
under all operating conditions, (2) support the machine's weight and load, and distribute it
uniformly and evenly to the soil or main support structure, (3) maintain established
equipment locations, and (4) minimize transmission of vibration to or from the machines.


Chapter 2
Installation
2-2 P500.chap02.07/02/2007


While the responsibility for supplying an ample foundation rests with the purchaser, the
following recommendations should be considered:

1. The Outline Drawing provides equipment mounting surface areas, mounting pad
locations, equipment weight, main piping connections, and other information necessary
in designing a foundation.

2. A foundation of reinforced concrete should be of ample size and proportion for
adequate support of the machinery.

3. Provision should be made in the foundation design for accessibility to all parts of the
machine or its auxiliaries during operation, inspection and maintenance.

4. The foundation should rest entirely on natural rock or entirely on solid earth. A
foundation resting partly on one and partly on another may warp due to settling of part
of the foundation support. Distortion may also occur due to unequal pressures created
by differences in ground water level.

5. Foundations supported on pilings should have a rigid continuous cap over pilings on
which the foundation rests.

6. Temperature surrounding the foundation should be uniform. Temperature differences
between the top slab and mat, for instance, can create substantial bending stresses in
columns. Care must be taken to reduce thermal distortion from radiation or uneven
heating and cooling. Direct sunlight on outdoor tropical installations is to be avoided.
Steam lines passing close to the foundation should also be avoided; but when
unavoidable, they should be insulated and the foundation shielded.

7. Foundation should be isolated from all other structures and arranged so that outside
vibrations are not transmitted to it. Where floor beams must support foundations, a
vibration dampening material should be installed between the beams and the
foundation.

8. Design of foundation structure should avoid resonant frequencies at driver speed.

9. It is recommended that concrete foundations be allowed to cure for approximately 28
days before loading. This will allow for development of strength and reduction in
shrinkage rate. Curing procedure should be in accordance with American Concrete
Institute recommendations.

MOUNTING ARRANGEMENT

The Polaris Compressor models covered by this manual do not require a special
foundation or the use of anchor bolts. These compressor models are designed to be placed
directly upon a flat, level surface of sufficient strength to support the compressor package.

Chapter 2
Installation
P500.chap02.07/02/2007 2-3


MOTOR MOUNTING HARDWARE

Before installing the main drive motor, carefully review the main motor and coupling
instruction manual with special attention to safety, wiring, lifting and alignment.

Units that require the main drive motor to be mounted on site are provided parts to permit a
proper installation. Parts provided include motor mounting blocks, shims, caution label,
conduit hardware and motor mounting hardware. An accurate shaft gap (bull gear shaft to
main motor shaft) and distance from the top of the baseplate to the centerline of the motor
and bull gear are critical for a proper installation. These values can be found on the
Compressor General Data Page in the Equipment Data section of this manual.

Installation Steps

1. Blocks are tapped both sides, allowing for orientation to either side of motor.
Blocks to support greatest possible area of motor feet. Bolt blocks to motor
feet using 0.12 inches (3mm) shims under each foot. Sleeve the bolts to
center the bolts in the hole of the motor mounting foot.
2. Place motor-block assembly on the baseplate. Gap the shaft ends at the
value shown on the Compressor General Data Page.
3. With the motor at its mechanical center and the bull gear against the thrust
face of the bearing toward the motor, position the motor such that the distance
between the shafts is equal to the value given on the Compressor General
Data Page. Take measurements at four locations, 90 apart, with an inside
micrometer. Adjust motor position to obtain equal distance (within .001 inch
(.025mm)) between the coupling faces at the four locations.
4. Rough align motor centerline height above the compressor shaft, by the value
given on the Compressor General Data Page.
5. Tack weld around blocks.
6. Weld all around blocks in increments to limit distortion.
7. Remove sleeves from around bolts.
8. Re-align motor to those values shown on the Compressor General Data Page
and bolt motor in place. See section SHAFT ALIGNMENT located in this
chapter for alignment instructions.
9. Couple motor to compressor.
10. Apply caution label to main conduit box of motor.
11. Trim shims if necessary.
Chapter 2
Installation
2-4 P500.chap02.07/02/2007


12. Reference the Field Wired Connection Diagrams in Chapter 10-Technical
Drawings to assure that all instrument connections from the motor are made to
their correct final destination.
WARNING
CURRENT TRANSDUCERS (MAT) CAN BE
HAZARDOUS. THEY CAN DEVELOP A LETHAL
VOLTAGE AND SELF-DESTRUCT IF THE
SECONDARY IS OPEN WHEN THE PRIMARY
CURRENT IS PRESENT. BEFORE DOING ANY
INSTALLATION WORK, BE SURE TO DISCONNECT
ANY POWER SOUCE INVOLVED WITH THE
TRANSDUCER. UNDER NO CIRCUMSTANCES OPEN
THE SECONARY LEADS OF THE CURRENT
TRANSDUCER WITH THE POWER SOURCE
ENERGIZED.
13. Customer to paint as required after assembly.
14. All conduiting to be supported as required reducing vibration to a minimum.

PIPING

Piping system design and fabrication is the responsibility of the customer. FS-Elliott
Company does not assume any responsibility for the piping system design or fabrication.
However, the following sections are offered as guidelines. This information is based on
good engineering practice and experience on a wide variety of installations.

It is recommended that specialists experienced with piping design for centrifugal compressor
installations do the piping system design. As an alternate, reference should be made to a
current reference such as CAGI Compressed Air and Gas Handbook section on dynamic
compressors.

All piping connected to the compressor must be properly supported, aligned and anchored
to avoid strains on the compressor. Do not use the compressor for anchoring or supporting
any attached piping except for control piping or tubing. The resultant forces and moments
due to air piping weight, thermal growth and reactions due to pressure variations must not
exceed the limits for the compressor inlet and discharge connections as shown in Figure 2-1.
Chapter 2
Installation
P500.chap02.07/02/2007 2-5

















FIGURE 2-1
ALLOWABLE FORCES AND MOMENTS

Piping flange bolt holes must be precisely aligned to eliminate the buildup of torque when
pulled together with flange bolts. Adjoining flange faces must be parallel to each other.

It may be possible to support and anchor the air piping and components so as not to exceed
the allowable forces and moments without the use of expansion joints; however, an
expansion joint must be used if required to meet the limits shown in FIGURE 2-1. Liners
should be used with expansion joints to minimize noise, flow disturbance and piping
excitations created by the convolutions. Dual tie rods are recommended. The expansion
joint manufacturer's selection and installation guidelines must be followed.

Caution
Piping strains imposed on a compressor may cause
misalignment of critical components resulting in
damage to the compressor.

The main air and water connection sizes for the standard compressors are listed in TABLE
2-1. Oil cooler water connection sizes may vary if optional coolers are selected. Verify
connection sizes with the unit outline drawing.

It is essential that all piping be thoroughly cleaned of dirt, weld slag, mill scale or other
foreign material before making final connections to the compressor. All protective flange
covers and plugs installed on the compressor for shipment should remain in place until
necessary to remove them when making the connections to the compressor.
0 100 300 400
500
0
100
200
300
F
o
r
c
e
s

P500
Allowable Forces and Moments
3
rd
Stage Discharge Flange
Note: Acceptable range below
lbf
(136)
(N)
(445)
(1335)
(890)
(272) (408) (544) (680)
(Nm)
ft-lbf

0 100 200 300 400 500
0
100
200
300
P500
Allowable Forces and Moments
1st Stage Inlet Flange
Note: Acceptable range below curve
(N) lbf
(1335)
(890)
(445)
F
o
r
c
e
s

Moments
(136) (272) (408) (544) (680)
ft-lbf
(Nm)
200
Moments
Chapter 2
Installation
2-6 P500.chap02.07/02/2007


Inlet Air Piping
A high quality inlet air piping system and a source of clean, dry air is essential for a
successful compressor installation. The following information should be thoroughly
reviewed prior to starting on the system design. FIGURE 2-2 shows a typical system
arrangement with additional guidelines. Allowable force and moment limits are listed in
FIGURE 2-1.

Caution
FS-Elliott Company must be contacted if the
compressor is to be connected into an inlet air
header or plenum that is common to any other
compressor. An inlet common to multiple units is
generally unacceptable due to potential operational
problems.

The standard clean inlet air system pressure drop used for aerodynamic design is 5.6 inches
(14.2 cm) of water total for the inlet filter and all piping between the filter and compressor
inlet. FS-Elliott Company should be advised if the air system design pressure drop exceeds
this value due to the possible effect on compressor performance.

Inlet piping must be constructed of corrosion resistant materials or protected with a suitable
internal coating to prevent the possibility of impeller erosion or other damage caused by the
ingestion of rust particles. Suggested materials are stainless steel, aluminum or rigid plastic.

The minimum inlet pipe diameter should be equivalent to, or larger than, the compressor
inlet connection size as shown in TABLE 2-1. Use gradual transition pipe sections when
changing diameters to minimize pressure drop and flow disturbance.

Table 2-1
Compressor Air & Water Connection Sizes

Air Water

Compressor Model
Inlet
Diameter
and Rating
Discharge
Diameter
and Rating
Intercoolers
Inlet &
Discharge NPT
Oil Cooler
Inlet &
Discharge NPT
Polaris 500 (3 Stage)
Polaris 500 (2 Stage)
10 - 150 RF
10 - 150 RF
See Note 4
1
1
1
1

Note
1. ANSI Class 150 drilling with Class 150 thickness.
2. All dimensions shown are standard and are in inches.
3. Connections should be verified with the unit outline drawing.
4. See Units Outline drawing.

Chapter 2
Installation
P500.chap02.07/02/2007 2-7

The compressor inlet air piping must be rated for vacuum pressure of 1.0 psia (0.07 bar).
Fabricated sheet metal ducts are not recommended for this service because they are
susceptible to collapse under the low-pressure conditions that may be experienced during
operation.

The inlet piping system should be as short as possible and designed with a minimum
number of bends and fittings to meet pressure drop and flow requirements described above.
The design should incorporate a sufficient number of flanges for ease of inspection and
cleaning. Mating flange faces must be parallel and bolt holes must be precisely aligned.

Each compressor includes a straight length of pipe located at the inlet. If sufficient space is
available, it is recommended that an additional straight section having a length equivalent to
four or more inlet pipe diameters be installed adjacent to the compressor inlet flange.

Compressors are furnished with inlet guides. The guide vanes are factory mounted and
shipped intact on all models.

FIGURE 2-2 shows an inlet piping installation arrangement.


Chapter 2
Installation
2-8 P500.chap02.07/02/2007


A. Optional inlet air filter/silencer with weatherhood.
B. Provide sufficient clearance around entire circumference to prevent binding on structure.
C. 6 ft. (2 m) min -- clearance above any horizontal surface.
D. Lagging - suggested for sound attenuation.
E. Manometer or optional air filter P transmitter (connect to air filter housing or to a point
on pipe near filter outlet).
F. Long radius elbow -- minimum diameter to be equal to compressor inlet flange.
G. Drain valve -- connect to open drain.

FIGURE 2-2
COMPRESSOR INLET AIR PIPING


Chapter 2
Installation
P500.chap02.07/02/2007 2-9

Units equipped with guide vanes include an inlet pipe section that terminates in a standard
flange for connecting to the customer's air piping.

Use a long radius elbow if the inlet piping must make a 90-degree turn near the compressor
inlet flange. Short radius or mitered elbows should not be used for any location in the inlet
piping system due to high-pressure drops and potential flow disturbance that may affect
compressor performance.

Condensate may collect in air piping at most installation sites, therefore, slope all horizontal
piping runs away from the compressor to prevent condensate draining back into the
compressor. Install valved drains in the low points of the piping to remove the condensate.

Inlet piping may be lagged to attenuate airborne and structure borne noise. Many
commercial pipe coverings are available for this purpose. Lagging, if installed, must be
arranged to permit accessibility to instrumentation installed in the inlet air pipe.

A conical metal screen may be temporarily installed in the air piping near the compressor for
added assurance of system cleanliness. It should be removed when it has been determined
that the system is clean.

A high quality dry type inlet air filter is required to prevent dirt and moisture from entering the
compressor and it may also reduce the noise level. Optional combination filter-silencers are
available to provide additional noise attenuation if required by site restrictions. As a
minimum air filters used with the Polaris Compressor must be capable of removing 97% of
all particles larger than 1 micron. Less efficient filters may damage compressor internals.

Typical filter-silencers furnished as accessory items are two-stage dry types that are rated
for maximum efficiency and are oversized for extended service life. They are available in
weatherproof designs suitable for outdoor installation. Each filter includes a pressure drop
measuring device for monitoring cleanliness. Alternate filter and filter-silencer designs such
as self-cleaning units are available as options.

Caution
Oil-Bath type filters must not be used with the
Polaris Compressor.

Install the inlet air filter with the inlet opening(s) located at least 6 feet (2m) above roof or
floor surfaces to minimize the entrance of debris. Locate the filter so that the discharge from
vents, pipes, stacks, cooling towers, etc., is prevented from entering the compressor. Some
of these discharged gases may form corrosive fluids when they come in contact with
moisture in the air and thus could damage the compressor internals and air piping system.
Outdoor locations subject to windy conditions should be avoided.

The inlet air source should be as cool as possible. Do not locate the filter in any area where
the maximum ambient temperature exceeds the specified maximum design compressor inlet
air temperature that is listed on the compressor data plate. Air temperatures in excess of
the specified maximum will have a negative effect on compressor aerodynamic
performance.

The filter must be adequately supported. It is recommended that a suitable platform or
access be provided for visual inspection of the filter and for maintenance purposes. Poorly
located filters usually lead to inferior filter maintenance.
Chapter 2
Installation
2-10 P500.chap02.07/02/2007


A pressure drop indicator is furnished with the optional filter supplied by FS-Elliott Company.
The typical indicator is a "U"-tube manometer that is to be field mounted. A pressure tap for
the manometer is typically located near the air filter outlet flange or, in some cases, on the
filter housing. The manometer should be positioned where filter cleanliness can be easily
monitored.

Sufficient tubing is supplied to locate the manometer in close proximity to the filter.
Additional non-corrosive tubing may be required if the manometer is to be remotely located
from the filter. Alternately, the pressure tap located on the filter can be plugged and a
tapped connection may be used in the inlet pipe on the upstream side of the inlet guide
vanes; i.e., between the filter and the guide vanes. All air connections to the manometer
must be air tight to avoid erroneous readings. Leak test the connections upon startup with a
soap solution. Generally, filters are to be serviced when the pressure drop increases by 10
inches (25 cm) of water above the clean pressure drop, however, this varies, and must be
checked with the vendor literature contained in the instruction book.

An available control system option features a differential pressure switch for monitoring the
inlet air filter pressure drop. The switch is to be field installed in a tapped connection that is
to be located between the air filter and the guide vanes. The manometer furnished with the
filter may be discarded if the optional differential pressure switch is furnished. Alternately, a
tee connection may be installed on the filter or inlet pipe so that one side may be connected
to the manometer and the other to the pressure switch.

Air Discharge and Atmospheric Bypass Piping
The design of the air discharge and atmospheric bypass piping is usually more complicated
than the inlet piping because of the higher pressures and temperatures encountered. The
following information should be thoroughly reviewed prior to starting on the design.

The typical air distribution system may include an aftercooler with moisture separator, a
discharge check valve, a block valve in the discharge air header, atmospheric bypass valve
and silencer, air receiver, expansion joint(s) and pipe with control connections, fittings,
gaskets, hardware, hangers and supports. The system should be arranged so that the
compressor, aftercooler, and air receiver are as close together as possible (use of 90
elbows is recommended to reduce piping strain). Refer to FIGURE 2-3 and FIGURE 2-4 for
relative component locations and further details on the discharge air system.

Chapter 2
Installation
P500.chap02.07/02/2007 2-11

If the Polaris Compressor discharge is connected to a manifold common to other
compressors, it must be completely isolated from any pulsating airflow such as that
produced by reciprocating compressors. This can be accomplished by connecting the
Polaris Compressor directly to an air receiver or to a point downstream of the air receiver
or other pulsation-dampening device. If this is not done the pulsations may result in control
problems and possible damage to the air discharge check valve or the compressor.


WARNING
THE UNCOOLED AIR DISCHARGE FROM THE
COMPRESSOR IS HOT. THE AIR PIPING BETWEEN
THE COMPRESSOR AND AFTERCOOLER AND THE
ATMOSPHERIC BYPASS PIPING MUST BE
ARRANGED TO PREVENT CONTACT WITH
COMBUSTIBLE MATERIALS AND PERSONNEL.
FOLLOW APPLICABLE LAWS, CODES, INDUSTRY
GUIDELINES OR LOCAL SITE RULES REGARDING
PERSONNEL SAFETY IN THE VICINITY OF HOT AIR
LINES.

The maximum compressor discharge air temperature for these compressor models is
approximately 400 F (204 C). As a guide, the typical aftercoolers if used will reduce the
compressed air temperature to within 20 F (11 C) of the incoming cooling water
temperature.

Depending on system design, air piping may have a tendency to move under certain
operating conditions such as during abrupt load changes. Adequate guides, anchors or
supports must be installed to restrain the pipe and prevent excessive forces and moments
from acting on the compressor flange.

Chapter 2
Installation
2-12 P500.chap02.07/02/2007







FIGURE 2-3
AIR DISCHARGE ATMOSPHERIC BYPASS PIPING
(UNITS WITHOUT MOUNTED AFTERCOOLER)
Chapter 2
Installation
P500.chap02.07/02/2007 2-13




Chapter 2
Installation
2-14 P500.chap02.07/02/2007


The extensive variety of discharge air system arrangements precludes the possibility of
giving adequate coverage to the subject of piping force and moment calculations in this
manual. Calculations for flange loads must include all reactions due to piping system weight
and thermal growth. The resultant forces and moments transmitted to the air discharge
flange must be within the limits listed in FIGURE 2-1.

It is recommended that an expansion joint be incorporated in the discharge air piping system
to ensure that compressor flange load limits are not exceeded. As shown in FIGURES 2-3
and 2-4, the vertical pipe section extending from the compressor air discharge flange should
be turned to the horizontal direction as soon as possible or practical. The expansion joint
should be installed in the horizontal run near the elbow that connects the horizontal and
vertical pipe sections. The tee connection for the atmospheric bypass line should be on the
downstream side of the expansion joint and upstream of the aftercooler.

Expansion joints should include a liner and two tie rods. When the expansion joint is
installed the tie rods must be oriented in a horizontal plane in order to allow for the correct
freedom of movement.

The pressure rating of the discharge air piping must be suitable for compressor surge
pressure levels. Use one hundred and twenty percent (120%) of the rated absolute
compressor discharge pressure as the maximum operating pressure level. The suggested
hydro test pressure level for system components is one hundred and fifty percent (150%) of
the surge pressure.

Piping in the discharge air system is subject to condensate buildup at various times.
Horizontal runs must slope away from the compressor to prevent condensate draining back
into the compressor. Adequate drain connections with valves or traps are recommended at
all low points in the system to drain the condensate. Manually operated drain valves, if
used, should be positioned for easy access.

Use gradual transition pipe sections when changing diameters. Avoid the use of short
radius elbows and minimize the number of fittings and turns that are major contributors to air
system pressure drop.

An atmospheric bypass valve is furnished with each compressor and is shipped loose for
mounting by the customer. It is recommended that the valve be located a maximum of 30
equivalent pipe feet (9.1 m) from the compressor discharge connection in order to ensure
good control response.

The atmospheric bypass line is to be connected to a tee connection located in the air
discharge line from the compressor. The bypass piping between the tee and the bypass
valve should have the same pressure rating as the air discharge piping. Piping on the outlet
side of the bypass valve may be of a lower rating, if desired, since it is discharging to the
atmosphere.

Chapter 2
Installation
P500.chap02.07/02/2007 2-15

The design pressure drop in the bypass piping is important for satisfactory control operation.
The total pressure drop of the entire bypass piping, including all components except the
atmospheric bypass valve, must not exceed 47% of the rated compressor discharge
pressure (absolute) when passing 110% of the design flow. Use 2 psig (0.1 bar) for the
bypass silencer pressure drop.

The diameter of the atmospheric bypass line should be equal to, or larger than, the
compressor discharge connection size shown on the compressor outline. Use gradual
transition pipe sections for connection to the bypass valve. Refer to the valve drawing
located in the Accessory-Chapter 8, to confirm the valve connection size.

The pipeline type silencer is recommended for installation downstream of the atmospheric
bypass valve. The diameter of the line between the valve and the silencer should be equal
to, or greater than, the compressor discharge connection size. It should include a gradual
transition section to set up to the silencer inlet connection size in order to maximize sound
attenuation. The diameter of the line extending from the silencer outlet to the atmosphere
should match the silencer outlet connection size. Smaller line diameters, if used, will
generally increase the noise level and pressure drop.

The discharge extending from the silencer to the atmosphere should be arranged to prevent
the entrance of rain, snow or dirt, and should be directed away from the compressor inlet.

WARNING
AIR DISCHARGED FROM THE ATMOSPHERIC
BYPASS LINE IS HOT. DO NOT DIRECT THE
BYPASS INTO OR NEAR AREAS OCCUPIED OR
USED BY PERSONNEL.

An air discharge check valve is required for all installations to prevent reverse airflow
through the compressor while running unloaded. The check valve should be installed in the
discharge air header immediately downstream of the tee connection for the atmospheric
bypass valve line. Air at this point is hot and unsaturated that will extend service life of the
check valve. Check valves require routine maintenance; therefore the valve should be
located so that it is accessible for servicing, in accordance with the valve manufacturer's
recommendations.

Caution
Install the check valve with airflow in accordance
with the directional arrow located on valve housing.

Chapter 2
Installation
2-16 P500.chap02.07/02/2007


Some air systems include a customer installed aftercooler to reduce the compressed air
temperature and moisture content. These installations use a pipeline type aftercooler with a
cyclone separator connected directly to the air discharge of the cooler. Condensate from
the separator should be piped to an open drain and should include a notched valve or trap in
the drain line. The trap or valve should be located so that they are accessible for service.

When designing the supports for an aftercooler/separator assembly, be certain to include
the weight of the liquid coolant. This information is found on the cooler data sheets of
optional aftercoolers purchased from FS-Elliott Company

An available aftercooler discharge air temperature option features a temperature probe for
monitoring the air temperature from the aftercooler. The probe is to be installed in a tapped
connection (usually 1/4 inch NPT) downstream of the aftercooler. Field wiring, which is
covered in the controls section of this instruction book is required to connect the probe and
the control panel.

The system pressure signal is to be taken from a tapped connection downstream of the
check valve. The system pressure signal is connected to the side of the panel (SPT). A
manual shut off valve is recommended in the sensing line for maintenance purposes.

A positive shutoff valve must be installed in the compressor discharge air pipe on the
downstream side of the check valve to isolate the compressor from the air system. The
check valve is not to be considered as an alternate to the positive shutoff valve. A check
valve failure on a pressurized system not having a shutoff valve could result in reverse
rotation of a non-operating compressor. This, in turn, could result in severe mechanical
damage to the compressor and driver due to inadequate lubrication or possible injury to
personnel if servicing the compressor.

WARNING
THE POSITIVE SHUTOFF VALVE IN THE
DISCHARGE AIR SYSTEM MUST BE CLOSED WHEN
SERVICING THE COMPRESSOR TO AVOID
POSSIBLE MECHANICAL DAMAGE OR PERSONAL
INJURY. THE VALVE SHOULD BE TAGGED OR
LOCKED IN ACCORDANCE WITH SITE RULES TO
PREVENT OPENING OF THE VALVE DURING
MAINTENANCE.

Cooling Water Piping
A coolant supply is required for each Polaris Compressor and the usual coolant media is
water. FIGURE 2-5 is a schematic showing a typical cooling water piping arrangement for
the intercoolers, aftercooler, and oil cooler.

Chapter 2
Installation
P500.chap02.07/02/2007 2-17

Water connection sizes are on the utility list located in the Equipment Data section of this
manual. Options affect the cooling system components and arrangement; therefore refer to
the compressor outline for details on the actual number, size and location of water
connections.

Cooling water supply pressures are to be limited to a maximum of 125 psig (8.6 bar) gage
for the intercoolers and 150 psig (10.3 bar) gage for the standard oil coolers. Customer
supplied water system piping should be rated consistent with water supply pressure.

For Pressure drops and cooling water flow rates for the intercoolers and oil coolers refer
to the Utility List located in the Equipment Data Section of this manual.

Note
An insufficient pressure drop across the cooler
connections or insufficient water flow will result in
inadequate cooling.

Inlet temperature of the cooling water supplied to the compressor should be equal to, or less
than, the customer specified maximum water temperature. Water inlet temperature
exceeding the design value will have a negative effect on compressor aerodynamic
performance and may also result in alarms or trips due to high lube oil or interstage air
temperature.

Water piping diameters should be selected on the basis of 5 to 8 ft/s (1.5 to 2.4 m/s)
recommended water velocity. Excessive water velocity will lead to erosion problems, noise
or insufficient heat transfer. Lower velocities will result in increased cooling water discharge
temperature and could lead to increased deposits.

Piping should be arranged so that excessive strains are not imposed on the intercooler or oil
cooler water connections. The piping should be completely flushed prior to making the final
connections to the coolers. Temporary screens, located upstream of the cooler inlet
connections, may be used to assure piping cleanliness. If used, they should be located near
the cooler inlets and then removed after it has been determined that the system is clean.

The water piping installation arrangement should be designed to include provisions for
cooler maintenance. Clearance required for removal of the intercooler and oil cooler tube
bundles is included on the compressor outline drawing. Consideration should be given to
the method of lifting that will be used to remove or install tube bundles for maintenance so
that the water piping does not interfere with the lifting apparatus.

Chapter 2
Installation
2-18 P500.chap02.07/02/2007



Throttling valves are required on the water outlet of the oil cooler, aftercooler, and
intercooler in order to maintain correct oil and air temperatures by adjusting water flow.
Manually operated globe valves are satisfactory for this purpose if water supply temperature
changes are gradual or seasonal. Automatic valves of the fail-open type are recommended
if temperature fluctuations are frequent or significant.

The extent of field-installed water piping instrumentation is a customer decision, however,
the following arrangement is suggested to assist in monitoring the water flow and cooler
performance.

Install a temperature indicator (TI) in the water inlet to each cooler. If the coolers are
supplied from a common header one TI, located in the header near the compressor, is
sufficient. TIs, if installed in cooler outlets, should be located between the cooler outlet and
the throttling valve (Refer to FIGURE 2-5).

A pressure indicator (PI) is recommended for installation in the water inlet and outlet of each
cooler for monitoring pressure drop. The PIs should be located close to the cooler water
connections on the outlet side of shutoff valves in cooler inlets and on the inlet side of
throttling valves in outlets. (Refer to FIGURE 2-5).

Select scale ranges for the TIs and PIs so that the average readings during operation are
near mid-span. Use thermowells for mounting the thermometers and install shutoff valves
for the gages to allow for servicing of instruments during operation.

Chapter 2
Installation
P500.chap02.07/02/2007 2-19




Chapter 2
Installation
2-20 P500.chap02.07/02/2007


FIGURE 2-6
INTERCOOLER DRAIN VALVE

Several optional control features are available for the cooling water system. These include a
cooling water solenoid valve and a water pressure flow switch. A print of the cooling water
solenoid valve is issued when this option is purchased. The cooling water solenoid valve is
to be installed in the oil cooler water supply pipe or the supply header pipe depending on the
customer's requirements. Field wiring, which is covered in the CONTROLS section of this
manual, is required to connect the water solenoid and the control panel.

Intercooler Condensate Piping
Moisture is condensed as the compressed air is cooled between compression stages. The
amount condensed depends upon humidity conditions existing at site. The condensate
must be drained from the compressor.

Caution
Condensate collects in the bottom of the intercooler
shells and must be continuously drained. Failure to
drain the shells may result in damage to the
compressor due to water carryover.

FS-Elliott Company does not recommend the use of any type of drain trap for intercooler
drains. Experience has shown these to be unreliable for this service and they generally
have required high maintenance.

Each compressor is furnished with a self-cleaning, notched drain valve for each intercooler.
The valve is an adjustable gate type with a special notch machined in the bottom of the gate
as shown in FIGURE 2-6. The condensate drain line must be separately piped from each
intercooler shell to an open drain as shown in FIGURE 2-5. The outlet end of each drain is
to be positioned so that each may be individually observed during routine visual checks and
adjusted if needed.
Chapter 2
Installation
P500.chap02.07/02/2007 2-21

Caution
Keep each intercooler condensate drain line
separate from any other drain.


CONTROL SYSTEM FIELD WIRING AND PIPING
The following information is applicable to the standard microprocessor based control
system. The control panel is normally factory mounted on the compressor baseplate.
Control system components that are mounted on the compressor package are factory piped
and wired within the confines of the package.

Field wiring and piping is required by the customer to complete the control system
interconnection. The extent of the wiring and piping required is dependent on the purchased
control features. Specific details are shown on the drawings issued for each order. Field
connection points for control components are located on the side of the panel and are
identified with permanently attached engraved phenolic tags located on the panel exterior.

Environmental Limits
The standard electronic control system includes components that have temperature limits
that must be taken into consideration when planning the installation. Optional control panel
features may be required to meet site conditions as determined by the following temperature
dependent guidelines.

Temperature Required Control
Local to Compressor System Feature

32 to 110F (0 to 43C) None
(1)


Above 110F (43C) Panel Cooler

-20 to 32F (-29 to 0C) Panel Heater

Note: 1. Decrease the upper temperature limit to 105F (41C) if the
control panel is subject to direct continuous sunlight.

Caution
Temperatures exceeding the above limits may result
in control operational problems or possible damage
to components.

Field Wiring
The extent of field wiring required to complete the compressor installation varies depending
on the type of compressor driver and the purchased control system options. Wiring
requirements for field wired devices are shown on Connection Diagrams issued for each
compressor. Refer to Connection Diagrams. Additional wiring details on required devices
are covered in the following paragraphs.

Chapter 2
Installation
2-22 P500.chap02.07/02/2007


Required field wiring must be done in accordance with applicable codes and other site
restrictions. Drawing details on wire gage and length restrictions must be followed to ensure
proper control operation.

Power Supply
Each control panel requires a power supply having an isolation transformer with surge and
lightning protection. The required 1 kVA supply is single phase, 115 VAC +10% and 50-60
Hz. The transformer is available from FS-Elliott Company as an option.

Motor Driver Compressor
Compressors having motor driver overload protection include a current transformer. The
transformer is factory mounted in the main terminal box of the drive motor and is factory
wired to the compressor control panel.

If the drive motor is customer supplied the current transformer will be shipped loose for field
mounting by the customer in the main terminal box of the motor. Field wiring is required to
connect the transformer to the control panel as shown in the certified connection diagrams.
When drive motors are removed for shipment the transformer must be reconnected in the
field after installation of the motor.

A normally open "dry" relay contact is provided in the FS-Elliott control panel for the purpose
of starting and stopping the motor. The customer must wire this circuit into the starter's
start/stop circuitry. The customer must eliminate any possibility of starting the motor at the
starter.

A normally open relay contact for the drive motor status is required in the starter to indicate
that the starter circuitry is activated when the contact closes. The relay contact must be field
wired to the compressor control panel.

Optional Features
All compressor control panel piping connections are identified with permanent tags affixed to
the outside of the control panel. Field piping connections required for each compressor are
identified on the compressor outline drawing.

Field installed control piping should be of high quality non-corrosive materials, such as
stainless steel or copper. Piping runs should be kept as short as possible and must be
properly supported over their entire length. Avoid low spots to eliminate the possibility of
condensate buildup.

The diameter of field-installed piping must be equal to, or slightly greater than, the
connection size furnished on the compressor control panel. Excessive length or piping that
is either too small or large in diameter may result in sluggish control response.

Air supplied to the control panel and components must be of instrument quality; i.e., cool, dry
oil free and filtered.

All lines supplying air to the control panel should include a filter or separator and a shutoff
valve located in close proximity to the panel. Supply connections made to the air system
piping or air receiver should be located on the top of the pipe or receiver to prevent
condensate or dirt from entering the panel air supply line.
Chapter 2
Installation
P500.chap02.07/02/2007 2-23

The number of required field connections for control piping varies depending on control
system options. Refer to the following paragraphs on each connection. Connections are
located on the compressor outline drawing.


Control Air Supply

Control air is required by the seal air buffer system. Control air supplied by the customer to
a 3/8 NPT connection labeled L7 will supply air to the buffer system. Refer to the Outline
drawing and the P & I Diagram for the location of the L7 connection.

The control air supply should supply an uninterrupted supply of instrument quality air during
compressor operation. Supply pressure requirement is 10 to 100 psig (0.7 to 7.0 kg.cm
2
).
The supply air temperature should be limited to approximately 125F (52C). Normal control
air consumption is approximately 10.0 scfm under steady state conditions.

An optional vortex type air cooler with an integral fixed setting thermostat is required for the
panel if the site temperature exceeds the previously noted limit of 110F (43C).

The cooler air supply connection is located on the panel and is shown on the compressor
outline.

The required cooler air supply is approximately 25 SCFM at a minimum supply pressure of
80 psig (5.5 bar) gage with relative humidity less than 80%.


Inlet Guide Vanes
Compressors are furnished with electric actuated inlet guide vanes. If the compressor was
not purchased with the Electrical Package, then 110 VAC will need to be provided to the
Inlet Guide Vane Actuator. Reference the Field Wired Connection Diagram in Chapter 10.

Atmospheric Bypass Valve
For some compressor configurations, the atmospheric bypass valve will need to be field
installed as noted in the section on air discharge piping. The valve will need to have 110
VAC / 1 Phase provided to it. The 4-20 mA signal will also need to be wired from the control
panel to the valve. Reference the Field Wired Connection Diagram in Chapter 10 for details.

Caution
The Inlet Guide Vanes and the Atmospheric Bypass
Valve are factory set and calibrated. Do not attempt
to make adjustments. Call FS-Elliott Company for
service.
Chapter 2
Installation
2-24 P500.chap02.07/02/2007



MISCELLANEOUS FIELD WIRING

Compressor Drive Motor
Wiring for the compressor drive motor power supply is to be done in accordance with
connection details shown on engraved tags permanently attached to the motor housing.
Additional information is included in the manufacturer's instruction material and on the motor
outline drawing. A rotational check must be made prior to coupling of the motor and
compressor to ensure rotation is in accordance with the directional arrow attached to the
compressor gear housing.

WARNING
INCORRECT DRIVER ROTATION MAY RESULT IN
SEVERE DAMAGE TO THE COMPRESSOR AND MAY
ALSO AFFECT WARRANTY.

Compressors having motor overload control require one of the motor power leads to pass
through the opening in the motor amp transformer that is mounted in the main motor
terminal box. Refer to the connection diagrams for additional details.

The power supply requirements and wiring connection details for field connection of optional
motor space heaters is shown on the motor outline drawing.

Motor Starters
When optional drive motor starters are purchased from FS-Elliott Company they include the
necessary contactors or other provisions to interface with the compressor control system.
Starters furnished by others must also include these provisions, therefore all wiring drawings
should be thoroughly reviewed for complete starter requirements prior to procurement of the
starters.

LUBRICATION SYSTEM

Preparing for Initial Operation
The lubrication system is furnished with FS-ELLIOTT Corona brand oil. The following
procedure should be followed to ensure proper operation of the oil system.
1. Prime the main oil pump by removing the suction side of the pump connection and filling
the suction hose with FS-ELLIOTT Corona brand oil..
2. Start the startup oil pump through the control panel. If oil pressure does not develop
within 5 seconds, stop the pump. The oil pump is most likely running backwards.
Interchange any 2 of the 3 power leads to the control panel. This will reverse rotation of
the start-up pump located in the oil reservoir. Circulate oil for approximately 15 minutes
after ensuring correct pump rotation.
3. Inspect the oil piping for leaks and correct as required.
4. Check oil temperature and pressure values on the control panel display.
5. Adjust the cooling water flow and pressure control valve if necessary to bring the
temperature and pressure within the required range shown in the lubrication section of
this manual.
Chapter 2
Installation
P500.chap02.07/02/2007 2-25

SHAFT ALIGNMENT

Polaris Compressors are usually tested with their contract drivers and, unless there is a
shipping limitation, the compressor package is shipped with the driver mounted on the
baseplate. All drivers are aligned for factory testing, however, they must be checked for
alignment after completing installation of the compressor at the site and re-aligned if
necessary to bring within the specified tolerance. The alignment tolerances and
recommended procedures are outlined in the following sections.

Caution
Alignment must be checked and corrected if
required before initial compressor operation.
Supply lubrication to all bearings before rotating or
moving the compressor bullgear shaft or the driver
shaft.

Dowel pins are not factory installed in the driver feet due to the possible need for re-
alignment in the field. After final coupling alignment is complete, install dowels in the driver
feet as noted on the driver outline drawing. Pilot holes are usually provided in the driver feet
for dowels that are to be furnished by others.

Note
If the driver is removed from the baseplate for shipment,
the factory installed shims located under the driver feet
are secured to the driver mounting pads on the
baseplate or to the driver feet. These shims should not
be separated because they can be reinstalled for initial
vertical alignment when the driver is mounted in the
field.


The two types of misalignment depicted in FIGURE 2-7 must be checked and corrected, if
required, to meet the limits shown in TABLE 2-2. Angular displacement is a form of
misalignment in which the shaft centerlines intersect, but are not parallel. Parallel offset
indicates the amount of parallel misalignment between the centerlines of two adjacent shaft
ends.

When making the initial alignment, allowances must be made for thermal growth that occurs
when the compressor gear case and the driver change from ambient to normal operating
temperatures. Use the allowances listed in TABLE 2-2 for cold alignment of the driver
relative to the compressor. This is necessary to ensure collinear shaft alignment (FIGURE
2-8) during normal operation. Collinear alignment exists when shaft centerlines are parallel
and intersect.









Chapter 2
Installation
2-26 P500.chap02.07/02/2007



c
OFFSET
L
c
L

PARALLEL MISALIGNMENT

c
ANGULAR DISPLACEMENT
"A" "B"
L
c
L


ANGULAR MISALIGNMENT

FIGURE 2-7
TYPES OF MISALIGNMENT






c
L
c
L


FIGURE 2-8
COLLINEAR ALIGNED SHAFTS
Chapter 2
Installation
P500.chap02.07/02/2007 2-27

TABLE 2-2
Cold Alignment Setting

Compressor
Driver
Allowances
Without Sound Enclosure

With Sound Enclosure
Motor Motor Centerline .005 in. (.13 mm)
Above Compressor Centerline
Motor Centerline .010 in. (.25 mm)
Above Compressor Centerline.


Pre-Alignment Checks

1. Be certain the driver is level and square relative to the compressor gear case.

2. Ensure the gear case and driver rest firmly on the baseplate, with equal loading at each
hold-down bolt.

3. Tighten all equipment hold-down bolts.

Motor Magnetic Center
If the air compressor is driven by an electric motor, the following procedure should be used
to determine the magnetic center of the motor.

1. Uncouple the motor from the compressor.

2. Fasten the motor coupling sleeve to the coupling hub, if the sleeve is mounted on the
hub, so that the sleeve is secure during solo operation of the motor.

3. Ensure that the motor bearings are lubricated. Refer to the lubrication plate mounted
on the motor housing or motor instruction information.

4. Start the motor. Check the direction of rotation by comparison with the directional
arrow attached to the coupling end of the motor or the arrow on the compressor
gearbox.

5. While the motor is running, locate the magnetic center that is its normal axial position
during operation. This is done by lightly scribing a mark on the shaft. The suggested
location is at the point where the shaft extends from the bearing housing.

6. Stop the motor. If the rotation is incorrect, reverse the motor power leads and recheck
the rotation before proceeding.
Chapter 2
Installation
2-28 P500.chap02.07/02/2007


Distance Between Shaft Ends (BSE)
Establish the proper distance between shaft ends (BSE) before proceeding with alignment of
the driver and compressor. The BSE dimension is shown on the certified compressor
outline drawing. Use the following procedure to obtain the BSE dimension.

1. The compressor bullgear shaft must be moved toward the motor. This is its normal
axial operating position relative to the driver.

2. Place the motor shaft on its previously determined magnetic center.

3. When the shafts are correctly positioned relative to each other, use an inside
micrometer to measure the distance between the shaft ends. Refer to FIGURE 2-9.

4. Place a dial indicator at the outboard end of the driver and move the driver as required
to obtain the proper distance between shaft ends.

5. Use an inside micrometer to recheck the distance between the shaft ends.


c
INSIDE MICROMETER
L
c
L



FIGURE 2-9
DISTANCE BETWEEN SHAFT ENDS



Reverse Indicator Method of Alignment
Preparation and use of a shaft alignment map, as shown in FIGURE 2-14, is recommended.
A shaft alignment map provides a convenient form on which to record indicator readings and
calculate equipment moves. Maintaining this information for comparison during
maintenance inspections or for future reference can provide valuable diagnostic information
should problems develop.

The reverse indicator method of alignment is recommended when the distance between the
adjacent shaft ends is greater than one-half the coupling diameter. The procedure is
explained below. An example of reverse indicator alignment is also provided later in this
section. Blank map forms are provided in this book.

Chapter 2
Installation
P500.chap02.07/02/2007 2-29

Constructing the Shaft Alignment Map
Record the compressor identification number(s), date and other information on the alignment
map (FIGURE 2-15). Construct the alignment map using the following procedure. Refer to
the example shown on FIGURE 2-14 for further guidance.

1. Mark the horizontal axis using a convenient scale, such as 1/4 inch per division.

2. Mark the vertical axis with .001 inch per division. This coordinate has been expanded
to clearly show misalignment.

3. Measure distances from the end of the compressor shaft to the following points:

A. Driver shaft end.
B. Centerline of the driver's inboard support foot hold-down bolts.
C. Centerline of the driver's outboard support foot hold-down bolts.

Pilot these distances as vertical lines. This is the same as the one drawn for the "END
OF COMPRESSOR SHAFT" as shown on FIGURE 2-14.

4. The solid, horizontal lines on the shaft alignment map represent the hot collinear shaft
alignment. If the compressor and driver grew the same amount thermally, then the cold
alignment would be the same as the hot alignment. However, since equipment usually
does not grow the same amount thermally, one machine must be set lower relative to
the other machine.

The compressor is factory doweled, therefore it should remain fixed and the driver
should be moved to its desired cold alignment setting relative to the compressor. Refer
to TABLE 2-2 for the recommended cold alignment setting.

5 Use a dashed line to indicate the desired cold position of the driver shaft in the vertical
view. In our application, thermal growth does not effect the alignment in the plan view,
therefore the desired cold position of the driver shaft in the plan view is collinear with
the compressor shaft.

Note
Assume the NORTH, EAST and WEST directions are as
shown on the alignment map example (FIGURE 2-14).

Alignment Procedure
The reverse indicator method involves taking readings from one shaft to the rim surface of
the adjoining shaft and vice versa as shown in FIGURE 2-10. This method of shaft
alignment eliminates the need for taking face readings.

1. Any piping strain on the equipment must be corrected before proceeding.

2. When spanning the coupling gap with an indicator bracket, zero sag is impractical to
achieve, therefore the actual amount of sag should be determined and recorded on the
alignment map. To determine sag in the bracket, attach the bracket to a rigid pipe. A 4-
inch schedule 40 (approximately 100 mm I.D. X 6 mm wall thickness) or similar size
pipe is adequate. With the pipe and attached bracket in the horizontal plane, and the
dial indicator reading off the top of the pipe, set the dial indicator on zero. Then rotate
the pipe 180 so that the dial indicator is reading off the bottom of the pipe. This
Chapter 2
Installation
2-30 P500.chap02.07/02/2007

indicator reading is the amount of sag in the bracket and is to be expressed as a
negative value.

Note
It is recommended that the bracket sag be recorded on
the alignment map. Failure to consider the sag can result
in gross misalignment.

3. Make a mark on the outside diameter of the driver coupling hub and compressor
coupling hub using a felt pen or chalk.

4. Attach the indicator bracket to the driver coupling hub. Attach the dial indicator to the
bracket so that it indicates off the compressor coupling hub. Refer to FIGURE
2-10.


c
DIAL INDICATOR
L
c
L


FIGURE 2-10
REVERSE INDICATOR READINGS


5. Rotate the driver shaft until the dial indicator is at the top dead center position of the
compressor hub (0 position). Rotate the compressor shaft until the mark on the
compressor hub (Step 3, above) is located at the top dead center position (0 position).
Set the dial indicator on zero.

Note
When taking dial indicator readings as noted in all the
following steps, be certain to record both the numerical
value and algebraic sign of each reading.


6. Rotate the driver shaft and the attached dial indicator 90 toward the EAST direction.
The EAST direction is an assumed direction as shown on the alignment map (FIGURE
2-14). Rotate the compressor shaft 90, also to the EAST direction, so that the mark on
the compressor hub aligns with the dial indicator. Record the dial indicator reading on
the alignment map at the "DRIVER TO COMPRESSOR" 90 position. Repeat this
procedure for the 180 and 270 positions and record reading. Upon return to the top
position, the indicator should return to zero. It is recommended that this step be
repeated to verify readings.

7. Remove the indicator bracket from the driver coupling hub and mount it on the
compressor coupling hub. Attach the dial indicator to the bracket so that it indicates off
the driver coupling hub.
Chapter 2
Installation
P500.chap02.07/02/2007 2-31

8. Rotate the compressor shaft until the dial indicator is at the top dead center position of
the driver hub (0 position. Rotate the driver shaft until the mark on the driver hub
diameter (Step 3) is located at the top dead center position (0 position). Set the dial
indicator on zero.

9. Rotate the compressor shaft and the dial indicator 90, also toward the EAST direction,
so that the mark on the driver hub aligns with the dial indicator. Record the dial
indicator reading on the alignment map at the "COMPRESSOR TO DRIVER" 90
position. Repeat this procedure for the 180 and 270 positions. On return to the top
position, the indicator should return to zero. Repeat this step to verify readings.

10. Using the equations shown below, calculate the alignment adjustment values A, B, C
and D:

A =Compressor to Driver 180 Reading - Bracket SAG) /2

B =(Driver to Compressor 180 Reading - Bracket SAG) /2

C =(Compressor to Driver 90 Reading - 270 Reading) /2

D =(Driver to Compressor 90 Reading - 270 Reading) /2

Note
Indicator bracket sag is a negative value. Also note that
no correction for sag is required on the EAST and
WEST side readings.

11. Plot the points calculated in Step 10 on the shaft alignment map in accordance with the
example shown in FIGURE 2-11. Then, starting at point "B" on the alignment map,
draw a straight line through point "A" and continue the straight line to the outboard end
of the driver. Likewise, starting at point "D" on the alignment map, draw a straight line
through point "C" and continue the straight line to the outboard end of the driver.

-4
-3
-2
-1
+4
+3
+2
+1
-C +D
+C
-A
+A
-D
+B
-B
+1
+2
+3
+4
+1
+2
+3
+4
-4
-3
-2
-1
-1
-2
-3
-4
+4
+3
+2
+1
-1
-2
-3
-4
END OF PAP
COMPRESSOR
SHAFT
END OF
DRIVER
SHAFT
PLAN VIEW
VERTICAL VIEW


FIGURE 2-11
PLOTTING ALIGNMENT VALUES ON MAP


Chapter 2
Installation
2-32 P500.chap02.07/02/2007


12. At the driver inboard foot on the alignment map, read the distance between the straight
line that was drawn in Step 11 and the desired cold position line. Likewise, at the driver
outboard foot, read the distance between the straight line that was drawn in Step 11
and the desired cold position line.

13. Before making adjustments, install dial indicators near the driver support feet and
outboard end of the driver as shown in FIGURE 2-12. The dial indicators should have
dual gages as shown in FIGURE 2-13. Set the dial indicators on zero and record the
readings of the small dial indicator gage.

WEST EAST
DIAL INDICATOR
DRIVER INBOARD SUPPORT
DIAL INDICATOR
DRIVER OUTBOARD SUPPORT
DIAL INDICATOR
DRIVER OUTBOARD END

FIGURE 2-12
DIAL INDICATOR LOCATIONS

14. Loosen the driver hold-down bolts. Raise one end of the driver, make the necessary
change in shim thickness under the driver feet and then lower the driver. Repeat this
on the other end of the driver.

Note
Be careful not to bump the dial indicators while adjusting
shim thickness under the motor feet.

15. After raising and lowering the motor, the dial indicators will no longer read zero. Move
the motor until the dial indicators read zero again.

Note
Be sure that the small gages on the dial indicators read
the original value that was recorded in Step 13 above,
since the large gage on the dial indicator may have
rotated more than a full turn.
Chapter 2
Installation
P500.chap02.07/02/2007 2-33

90
80
70
60
50
0
10
20
30
40
0
1
2
3
4
5
6
7
8
9
LARGE GAGE
SMALL GAGE

FIGURE 2-13
DUAL GAGE DIAL INDICATOR

16. Move the driver in the EAST or WEST direction (FIGURE 2-12) until the dial indicators
read the necessary EAST or WEST adjustment. Tighten the driver hold-down bolts and
recheck the alignment and distance between shaft ends (BSE).

17. Install dowels in the motor feet after correct alignment has been attained.

Alignment Example
1. Start to draw the map by selecting a convenient scale for the horizontal axis and draw
lines to indicate the following:

Compressor shaft end at coupling
Driver shaft end
Driver inboard support foot hold-down bolt centerline
Driver outboard support foot hold-down bolt centerline

2. Draw the desired cold position of the driver shaft. Thermal growth of the compressor
and driver is the same in the PLAN (TOP) VIEW, therefore the desired cold position of
the driver is drawn in line with the compressor shaft.

Thermal growth of the compressor is greater than the example motor driver in the
VERTICAL VIEW, therefore the desired cold position of the driver shaft is drawn above
the cold position of the compressor shaft. In this example, the motor shaft is .005 inch
higher than the compressor shaft.

For actual field alignment use the cold alignment settings shown in TABLE 2-2 for the
specific compressor model and driver type.

3. Assume an indicator bracket sag of -.002 inch for the example and record this on the
map.

4. The example rim readings for both shaft ends are recorded on the map.

5. Calculate the values for A, B, C and D using the equations given in Step 10 above.
Answer (in thousands of an inch): A =+5: B =-3: C =-6; D =+9

6. Plot the values calculated in Step 5 above. Refer to FIGURE 2-11.
Chapter 2
Installation
2-34 P500.chap02.07/02/2007


7. Draw a straight line through points "C" and "D" in the PLAN VIEW and another through
"A" and "B" in the VERTICAL VIEW. These lines represent the actual position of the
driver shaft with respect to the compressor shaft.

8. Then, doing an actual alignment, the dual gage dial indicators (FIGURE 2-13) would be
positioned as shown in FIGURE 2-12. The large dial would be set at zero and the
reading on the small dial would be recorded.

9. The distance between the actual driver shaft position and the desired cold position
represents the amount of movement required in order to obtain the desired cold
position. In this example, the outboard feet of the driver would have to be move toward
the WEST .006 inch and raised .018 inch. The inboard feet would have to be move
toward the EAST .004 inch and raised .011 inch to obtain the desired cold position.



Chapter 2
Installation
P500.chap02.07/02/2007 2-1
P
5
0
0
.
c
h
a
p
0
2
.
0
7
/
0
2
/
2
0
0
7









2
-
3
5

FIGURE 2-14
SHAFT ALIGNMENT EXAMPLE
Chapter 2
Installation
P500.chap02.07/02/2007 2-39
USER SERVICE EQUIP. NO. DATE
COUPLING TYPE LUBE AMBIENT TEMP. NAME
NOTES: ALIGNMENT METHOD ALIGNMENT BAR SAG MILS/MM
1) Show North in Plan view of sketch.
2) Mark compass direction in circles.
3) If offset value is plus, projected center
line of machine that the indicator was
attached to will be above the coupling
mark of the opposite machine.
4) If offset value is minus, projected center
line of machine that the indicator was
attached to will be below the coupling
mark of the opposite machine.
LEFT RIGHT LEFT RIGHT
PICK A CONVENIENT SCALE SCALE PER DIVISION SUGGEST 1" OR 2" PER DIVISION
W TO E W TO E
PLAN
VERTICAL
V
o
Bot - Top
2
H
o
Ri ght - Lef t
2
=
= =
=
TOP
SIDE

FIGURE 2-15
BLANK SHAFT ALIGNMENT MAP
P
5
0
0
.
c
h
a
p
0
2
.
0
7
/
0
2
/
2
0
0
7








2
-
3
7











C
h
a
p
t
e
r

2











I
n
s
t
a
l
l
a
t
i
o
n




Chapter 2
Installation
2-38 P500.chap02.07/02/2007

NOTES
Chapter 2
Installation
P500.chap02.07/02/2007 2-39

OFF DESIGN CONDITIONS

The rated conditions of the air compressor unit are listed on the equipment
nameplate. Operation of the unit beyond the rated conditions affects the performance
of the compressor. These factors need to be considered in the design of the unit's
installation.

The barometric air pressure at the plant should closely agree with the rated
barometric air pressure. An actual barometric air pressure below the rated barometric
air pressure will reduce the pressure capabilities of the compressor.

The ambient air temperature should be below the rated inlet air temperature of the
unit. An actual inlet air temperature above the rated inlet air temperature will reduce
the pressure capabilities of the compressor. The unit's control system can
compensate for the lower inlet air temperatures. As a result, the inlet air filters should
be located at a source of cool, clean, dry air.

The temperature of the cooling water should be below the rated cooling water
temperature. An actual water temperature above the rated water temperature will
result in increased interstage air temperatures and/or oil temperatures. Higher than
design interstage air temperatures reduce the pressure capabilities of the
compressor. High oil temperatures can result in premature bearing wear.

The cooling water flow rates should be equal to or slightly greater than the rated
cooling water flows. Low cooling water flow rates can result in increased interstage
air temperatures and/or oil temperatures. Excessive cooling water flow rates can
result in erosion of the materials in the heat exchangers. The water pressure drops
on the unit's nameplate indicate the required pressure drop across the inlet and outlet
water connections of the heat exchanger in order to achieve the rated water flow.
These water pressure drops provide an indication of the required pressure drop
across the supply and return water headers. The unit's water flow requirements and
water piping losses should be considered in the design of the water system.

The driver speed should closely agree with the rated driver speed on the nameplate.
An actual driver speed below the rated speed will reduce the pressure capabilities of
the compressor. The electrical power system (motor driver) or steam system (turbine
driver) should ensure a constant rated speed. Transients in voltage or steam
conditions could have an adverse effect on the performance of the compressor and
reduce the life of the motor.


WARNING
IF OPERATING A TURBINE DRIVER; EXCESSIVE
TURBINE SPEEDS CAN RESULT IN SEVERE
MECHANICAL DAMAGE AND PERSONAL INJURY.
Chapter 2
Installation
2-40 P500.chap02.07/02/2007


POWER REQUIREMENTS

The power supply to the motor and starter must be capable of maintaining an
acceptable line voltage during both the starting period of the unit and while the unit is
in operation. The supply transformer KVA size and impedence should be sized to
minimize the voltage drop during start-up of the unit. Incoming motor feeder or motor
branch circuit conductors must be properly sized. The power feed must have a
disconnect means and be protected against overcurrent, ground fault, and short
circuit fault.

The line voltage must not drop below the coil voltage range of the starters contactors
and control circuit devices. Contactors and control circuit devices must not be
allowed to drop below 85% of the coils rated voltage. When the contactors and
control circuit devices are operating on the secondary voltage of the starters control
power transformer (CPT), the line voltage must not drop below 90% of the coils rated
voltage. Voltages below these limits may cause contactor chatter and could result in
contactor burnout and damage to the starter. Another source for possible contactor
chatter is a faulty remote input control signal(s). The line voltage should also not
exceed the upper coil voltage limit off 110% of the coils rated voltage.

The characteristics of the motor are also affected by a decrease in the supply voltage.
A lower voltage extends the acceleration time of the motor, reduces the torque output
of the motor, and increases the heating of the motor windings. The voltage at the
motor terminals must not drop below 90% of rated voltage during start-up. In the
case of a reduced voltage start, the voltage at the motor terminals must not drop
below 90% of the rated reduced voltage.

The plants power system should be reviewed prior to installation of the air
compressor unit(s). A record of the supply voltage to the power transformer (E
incoming
)
should be measured on a chart recorder. If this incoming power is from the local
utility, a record is usually available from the local power company. The minimum
voltage should be used for the evaluation. The power transformer must be sized to
minimize the voltage drop during start-up of the unit(s). If an existing power
transformer is being used, the total load on the transformer must be reviewed.
Voltage data from the transformer should be recorded. This data can be used to
determine the approximate load on the transformer.

The equations below can be used to determine the expected voltage at the unit during
start-up. The load on the power transformer and wires during start-up of the unit(s)
must be used for the evaluation. Motors with a high full load amperage, low voltage
(380V or 460V) are especially a concern in regard to voltage drops. The line in-rush
current (I
in-rush
) for the motor can be obtained from the supplier of the motor/starter. If
multiple units are involved, the evaluation must be based on a load at start-up for one
unit plus the loads during normal operation of the additional units.

Chapter 2
Installation
P500.chap02.07/02/2007 2-41


Voltage
start-up
= E
incoming
- (E
transformer drop
+ E
wire drop
)

E
transformer drop
= (V) (KVA
motor
+KVA
other
) (Z
transformer
)
Rated KVA

KVA
motor
= (3) (V) (I
in-rush
)
1000

E
wire drop
= (3) (Z
wire
) (L) (I
in-rush
)
1000


E
incoming
minimum voltage to the power transformer
V rated voltage of motor
I
in-rush
line in-rush current during start-up of the unit
Z
transformer
impedence rating from transformer nameplate
Rated KVA rated KVA from transformer nameplate
KVA
other
KVA load on transformer from other sources
Z
wire
impedence of wire
L length of wire


If the line voltage during start-up (Voltage
start-up
) is less than 90% of the motors rated
voltage OR less than 90% of the starter coils rated voltage, the potential exists for
damage to the starter and/or motor. In this case, the power system must be upgraded to
ensure trouble-free operation of the units.



Chapter 2
Installation
2-42 P500.chap02.07/02/2007

NOTES

POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 1 of 10




Customer:

Location

Field Representative

Factory Order:

Frame:

Date:


P400
P500

POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 2 of 10

This checklist provides practical guidance as to the various checks and inspections that may be required to
install and start a POLARIS air compressor. This list is not intended to provide 100% of the requirements that
may actually be necessary to successfully install and commission a POLARIS compressor.

The services of an FS-Elliott Company service representative or an authorized distributor should be used for
assistance. Questions prior to the reps arrival may be directed to the distributor (or FS-Elliott field office).

Some items are listed in this form as being standard, optional, or provided by the customer. Refer to the
documents specific to this factory order to find out what was actually to be provided by FS-Elliott Company.

Recommended settings, adjustment methods, and scope of supply can change from time to time as
improvements are made.


Index

Section Description Page

I Initial Inspection and General Information 3 - 4

II Piping 4 - 6

A. Inlet Air Filter 4

B. Inlet Air Piping 4 - 5

C. Discharge Air Piping 5

D. Backplate Piping Strain Check 5

E. Oil Cooler, Intercooler, and Aftercooler 6

III Lubrication System 6 - 7

IV Driver and Alignment 7

V Control Panel 8

VI Start Up 9

VII Operational Records 9

VIII Miscellaneous 9





POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 3 of 10




I. INITIAL INSPECTION AND GENERAL INFORMATION

Initials Date Yes No
1 Does customer have a copy of the technical manual?
2 Has customers staff reviewed and understood the technical manual?
3 Was the utility list reviewed with customer? Is power supplied to the
oil heater, control panel, aux. oil pump, motor, motor space heaters,
governor, remote panel, etc.? Instrument air supplied? Water
supplied at the correct temperature and pressure?
4 Was the customer instructed on AC welding safeguards?
5 Are there any signs of any shipping damage or mishandling?
6 Have pictures of any damage been taken and submitted?
7 Date that compressor and parts were received
at site.

8 Were parts inventoried?
9 Was FS-Elliott advised of any shortages? If yes, when and by whom?
Customer Name:
Advised FS-Elliott
(name):

On:
10 Are there any signs of improper storage, rust, etc.?
11 Is unit subject to environmental extremes, dust, corrosives, moisture,
etc.? Describe the area where the compressor is located and the
source of the inlet air.
Location: Indoors, Outdoors, Clean, Dirty, Unacceptable
Source: Indoors, Outdoors, Clean, Dirty, Unacceptable

12 Are spare parts properly stored?
13 Is there adequate clearance around unit for maintenance? Refer to
outline drawing.
14 Is there proper grouting or use of jackmount pads (depending on
frame size)?
15 Is the baseplate level to within 1/16 over the length of the baseplate?
16 Is there any nearby equipment vibration?
17 What is the nature of the compressors usage?
Continuous, Weekly, Daily, Starts/Day, Standby,
other
18 Operating Mode? Base Mode, Suction Throttle, other
19 Was a list of recommended operating procedures developed and left
with customer?
20 And included in service report?
21 Was a list of recommended maintenance and troubleshooting
requirements developed and left with customer?
22 And included in service report?

POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 4 of 10
I. INITIAL INSPECTION AND GENERAL INFORMATION

Initials Date Yes No

23 Compressor Nameplate Data (located inside the control panel).
Serial
Number
Model
Driver Speed Rpm
Rated Inlet Capacity Cfm
Rated Inlet Air
Press.
psia (absolute)
Rated Inlet Temp
o
F
o
C
Rated Disch. Press. psig (gage)
Cooling Water Requirements
Inlet Water Temp
o
F
o
C
Max Inlet Water
Press.
psig (gage)
Water Requirements Flow (gpm) Pressure Drop (psid)
Intercooling
Oil Cooling
Aftercooling

II. PIPING
A. Inlet Air Filter (refer to technical manual)

Initials Date Yes No
1 Was the cleanliness of interior verified?
2 Is the housing properly located and installed? Minimum of 6 ft
above roof or grade and no source of contamination nearby.
3 Was a manometer and/or differential pressure switch installed?
4 Was customer instructed on the proper monitoring and
replacement of the inlet air filter (both stages)?
5 Is the filter housing easily accessible for maintenance?


B. Inlet Air Piping (refer to technical manual)

Initials Date Yes No
1 Were the drawing and notes for Compressor Inlet Air Piping
reviewed with the customer?
2 Was the piping made from a material resistant to corrosion, flaking,
or other problem that would cause impeller and diffuser erosion,
and also be able to withstand the vacuum pressure?
Recommended materials are stainless steel, rigid plastic, or
aluminum. Refer to pre-start manual.
3 Is the piping size the same diameter as inlet filter flange, and not
necked down until 5 pipe diameters before inlet valve?

POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 5 of 10
B. Inlet Air Piping (refer to technical manual)

Initials Date Yes No
4 Are all piping elbows long radius?
5 Was the piping clean? (blowdown is recommended).
6 Does the piping appear to have proper supports?
7 Is an inlet expansion joint installed?
8 Is the inlet expansion joint location correct?
9 Is a piping drain line installed?
10 Was the piping designed to minimize backplate deflection?

C. Discharge Air Piping (refer to technical manual)

Initials Date Yes No

1 Were the drawing and notes for Air Discharge, Atmospheric
Bypass Piping reviewed with the customer?

2 Was cleanliness of piping and last stage casing verified?
3 Is the piping size correct per the pre-start manual?
4 Is a block valve installed between compressor and plant air
system?

5 Was customer instructed on when to use the block valve?


6 Is the check valve installed in correct location (upstream of
aftercooler) and in proper orientation and flow direction?

7 Is the expansion joint installed in horizontal orientation with tie rods
correct. (refer to pre-start manual for guidelines).

8 Is the unloading line size equal or greater than the silencer inlet?.
9 Is the unloading valve installed close to unit?
Distance ft.

10 Is the discharge line, including aftercooler, sloped away from the
compressor?

11 Is the unloading silencer outlet protected from rain, etc.?
12 Are all items installed in proper relation to each other per the pre-
start manual?

13 Does the piping appear to have proper supports?
14 Was the piping designed to minimize backplate deflection?

D. Backplate Piping Strain Check (Refer to S.E.B. P-41)

Initials Date Yes No
1 Were backplate deflections recorded below?

Dial indicator readings (mils). +is towards gearbox, - is away.
1st Stage: Inlet Discharge
2nd Stage: Inlet Discharge
3rd Stage: Inlet Discharge


POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 6 of 10

E. Oil Cooler, Intercooler, and Aftercooler

Initials Date Yes No
1 What is the supply cooling water temperature?

o
F,
o
C
2 Compare to the utility list and the panel nameplate.
3 Is the cooling medium Water, Glycol mixture, the same as
shown in utility list?
4 Was customer instructed about the results of above design water
temperature on compressor performance?
5 Is the water flow correct (reverse direction) with respect to oil or air
flow
for oil cooler(s) Yes, No
for intercooler(s) Yes, No
for aftercooler Yes, No
6 Are inlet water valves installed for maintenance isolation?
7 Are outlet water valves installed at each cooler for flow control
regulation?
8 Are the notched drain valves piped separately to an open drain that
is accessible for operators
on first intercooler Yes No
on final intercooler Yes No
on aftercooler Yes No
9 Was customer instructed on the purpose of the notched drain
valves?
10 Were water leaks tested for and corrected?
11 Are pressure and temperature indicators installed in water lines?
(preferred)



III. LUBRICATION SYSTEM

Initials Date Yes No
1 Was the cleanliness of the oil reservoir verified visually? Wipe
interior with lint free rags.
2 Was an oil reservoir drain valve installed for maintenance
purposes?
3 What type of lubricating oil is used?

4 Does it meet recommended viscosity (ISO 32) and other guidelines
listed in technical manual?
5 Was oil reservoir filled between high and low level of sight glass?
6 Is the oil level correct in motor bearings (if applicable)?
7 Does the customer understand the results of running the auxiliary
oil pump for more than a few minutes without seal air?
8 Is the rotation of auxiliary oil pump correct?
9 Was the main oil pump primed?
10 Does the low oil level switch work?

POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 7 of 10
III. LUBRICATION SYSTEM

Initials Date Yes No
11 What is setting of oil reservoir heater?
o
F
o
C
12 Were any oil leaks found?
13 Were these leaks corrected?
14 Were these leaks documented and submitted per SEB P-100


IV. DRIVER AND ALIGNMENT

Initials Date Yes No

1 Was driver manual and/or nameplates checked for special
instructions (such as grease type)?

2 Was this information reviewed with customer?
3 Is the driver a Siemens motor?
4 If motor was supplied by FS-Elliott, was a motor pre-start
inspection checklist filled out?

5 Is the driver a turbine?
6 If turbine driver, was a turbine installation checklist filled out?
7 Were driver bearings properly lubricated with oil and flushed (if
applicable)?

8 Was grease added to motor bearings (if applicable)?
9 If turbine, is exhaust line equipped with a full flow relief valve or
rupture disc?

10 If turbine, was the overspeed trip operational and properly set?
11 If turbine, was customer advised of the effects of operation below
or above rated speed on compressor performance?

12 Was the correct driver rotation verified with coupling disconnected?
13 If motor, record solo motor amps
14 Were solo amps verified against low motor amp trip setting and
adjusted if necessary?

15 Were driver to compressor alignment readings and coupling
spacing included in service report?

16 Were any additional alignment shims used made of stainless steel
and the proper size?

17 Was the coupling installed correctly? Torqued, greased (if
applicable), and limited end float devices correct.

18 Was the driver doweled (preferred)?
19 If motor, do all strands of one phase of motor power pass through
the C.T.?

20 If motor, is reduced voltage start used?
21 Record % Seconds Delay
22 If reduced voltage start, were proper tap settings confirmed?




POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 8 of 10
V. CONTROL PANEL

Initials Date Yes No
1 Is a panel heater or a cooler required?
2 What is expected ambient temperature of panel?
3 Is a panel heater and/or a cooler supplied?
4 Were the shipped loose transmitters (if any) mounted?
Refer to transmitter list on the Control Panel Configuration Sheet
within Equipment Data section of technical manual and the
connection diagram for field wired devices.
5 Were the transmitters wired? Shielded wiring with twisted pair is
recommended.
6 Were the remote options (if any) properly wired?
7 Was tubing connected to transmitters and valves? 3/8" OD is
recommended.
8 Are the tubing connections at proper locations? Refer to pre-start
manual.
9 Is a manual shutoff valve installed in tubing line to optional SPT
(system pressure transmitter) for maintenance purposes?
10 Is all necessary wiring completed (AC and DC)?
11 Check for proper wiring connections?
12 Ensure connections were made at proper terminal boards?
13 Separate conduit for AC and DC wiring.
14 Are separate AC and DC grounds connected? Make sure that no
continuity exists.
15 Were temperatures and pressures on the DATA menu checked to
determine if transmitters were operational?
16 Was proper operation of the digital inputs and outputs verified?
17 Check the current date and time.
18 Check setpoints against Control Panel Configuration sheet in
technical manual. Record any changes in customers technical
manual.
19 Are the instrument air connections supplied with clean dry air?
20 Are provisions made for startup with an alternative source of
instrument air?
21 Were the control valves cycled from the panel?
22 Perform a simulated start-up with driver isolated. Did the panel
react in the correct manner? (driver fault)
23 Did the panel react in a correct manner when the driver was
started uncoupled?
25 Were all other checks in the applicable TSM completed?
26 Was customer instructed on the alarm and trip point limits and their
purpose?
27 Was customer instructed on what to do to investigate the various
alarms or trips (including driver fault)?


POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 9 of 10

VI. START-UP CHECKLIST
Initials Date Yes No

1 Was startup method reviewed and understood by customer?
2 Were proper operating log requirements established and provided
to the customer?

3 Was the purpose of the HOT MOTOR timer reviewed with
customer supervisor?

4 Was water flow to the coolers verified before start-up?
5 Was the oil reservoir filled to the proper level?
6 Was seal air pressure satisfied (<4 psig)? (if seal air option is
enabled)

7 What was the oil temperature before start-up?
8 Was the block valve open to the system?
9 Verify I/V in auto mode, U/V in auto mode, and record Control
Mode:

10 Was the purpose and location of the emergency shutdown switch
understood by the operator?

11 Customer to start-up unit per procedure found in operation section
of technical manual.

12 After start-up, adjust intercooler water valves to maintain interstage
air temperature 15
o
F above design cooling water inlet
temperature.

13 Adjust water flow to oil cooler to maintain 120 +/- 5
o
F oil
temperature to the bearings. If unit has AMOT bypass valve, then
record oil temperature
o
F

14 Record oil pressure psig at 120
o
F and adjust pressure valve
(if needed).

15 Confirm seal air relief valve setting (6.5 psig).


VII. OPERATIONAL RECORDS

Initials Date Yes No
1 Attach a completed operating data sheet. Monitor compressor until
temperatures stabilize. Record readings again after several hours
run time.
2 Determine discharge surge point and suction surge point. Record
surge test record in service report


VIII. MISCELLANEOUS

Initials Date Yes No
1 Were operations personnel trained?
2 Were any discrepancies documented using discrepancy form
3 Was compressor piping system schematic drawn and submitted
with service report. (Document: piping sizes, valve/trap locations,
receiver locations, etc. for water, compressor, instrument air, etc.)


POLARIS INSTALLATION / PRESTART CHECKLIST

Issued 07/02/2007 Form FSE-6061-
Page 10 of 10

NOTES
















































Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-1


PRINCIPLE OF OPERATION

Filtered air (controlled by an automatically operated inlet control device) enters the
compressor's first stage and is compressed. After initial compression, the air travels
through an intercooler where heat and moisture are removed from the compressed air.
After the air is cooled and dried, it enters the compressors second stage and is further
compressed. The air is then directed through a second intercooler to once again remove
heat and moisture. Finally, the air enters the compressors third stage, where it is
compressed to the design discharge pressure and supplied to the plant air system.

The compressors integral lubrication system supplies oil to the compressor bearings and
gears, while the water system supplies cooling water to the intercooler tube bundles and
the oil cooler.

The PLC control system automatically positions the inlet control device to maintain the
driver load within acceptable limits. Also, the unloading valve is automatically positioned
to maintain the design discharge pressure. Protective devices are implemented within the
control system to automatically shut down the compressor in the event that any of the
operating parameters reach an unacceptable level.

Surge is a common characteristic of centrifugal compressors. Surge occurs when the
compressor is unable to overcome the pressure of the plant air system. Surge may occur
due to atypical design conditions or abnormal control operations. When the compressor
experiences surge, the direction of airflow reverses as the compressor is attempting to
produce flow against the backpressure of the plant air system. In the event of a surge, the
control system automatically detects and eliminates the surge condition by unloading the
compressor (unloading valve opens).

CAUTION
Continuous operation of the compressor in the surge
condition will cause severe mechanical damage.


The PLC control panel is responsible for positioning the inlet control valve, positioning the
unloading control valve, positioning the interstage temperature control valves, sequencing
start-up and shutdown events, governing different modes of operation, monitoring
operating parameters, and providing alarm and trip indications. The control panel utilizes
an electronic microprocessor to perform these functions. Communication with the
microprocessor takes place via the PLC operator interface located on the front of the
control panel. Read Chapter 6 (Control System) prior to operating the compressor.
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-2

CONTROL
SYSTEM


UNLOADING
VALVE

AIR COOLERS
AND MOISTURE
ELIMINATION
SECTIONS

COMPRESSOR


INLET
CONTROL
VALVE


PLANT AIR
SYSTEM


LUBRICATION
SYSTEM


WATER
SYSTEM


















FIGURE 3-1
COMPRESSOR SYSTEM, BLOCK DIAGRAM


SAFETY PRECAUTIONS

1. Ensure all piping and electrical connections are secure before operating the
compressor.

2. Ensure that all valves, controls, and the trip and safety devices are functioning
correctly.

3. Review the operating precautions outlined in the drivers instruction manual before
the driver is operated.

4. Verify that the compressor drive shaft can be rotated by hand before starting the
compressor.

5. If rubbing, vibration, or unusual noises are detected during operation, stop the
compressor immediately to determine and correct the cause.

PREPARING FOR INITIAL START-UP

1. Disconnect the coupling between the compressor and driver.

NOTE
Gear type couplings must have the coupling sleeve secured
to the coupling hub with an adapter during uncoupled
operation.

2. Start the driver per the manufacturer's instructions and verify that the rotational
direction of the driver shaft is correct.

Filtered Air
Water Outlet
Facility Water Inlet
To Atmosphere
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-3

3. Connect the coupling between the compressor and driver (lubricate coupling as
necessary).

4. Inspect sight glass on oil reservoir for proper level. Should the oil level drop below
the bottom of the oil level sight gage when the pump is operated, oil should be
added until the level reaches the mid-point of the sight gage. Reference Chapter 5,
Lubrication Section for details.

5. Ensure that the backplate deflections are within the acceptable limits.

CURRENT DATE AND TIME

The current date and time are maintained by the real time hardware clock located in the
CPU314C-2PtP. The date and time can be adjusted using the following procedure.

1. Push the STATUS key on the PLC touch pad screen to access the general status
window (in the case of initial boot-up, the general status window appears after the
CONTINUE button is pressed on the start-up screen).


FIGURE 3-2
GENERAL STATUS SCREEN
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-4

2. Push the SETPTS function key to access setpoint screen 1.


FIGURE 3-3
SETPOINT SCREEN 1

3. Push the SETPT. 5 function key to access setpoint screen 5.


FIGURE 3-4
SETPOINT SCREEN 5
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-5

4. Setpoint Screen 5 displays the date and time setpoint fields. These (light blue) fields
are located on the left side of the screen. Setpoint Screen 5 also displays the current
date and time settings in the white field located on the right side of the screen. To
change the current date and time settings, continue to step 5.

5. Push the month setpoint field that and a keypad will appear. Enter the correct
month on the keypad then push the key to accept the new setting. Repeat this
process, and enter the correct day and year into their respective fields.

6. To set the correct time, push the setpoint field that represents the current hour and a
keypad will appear. Enter the correct hour on the keypad then push the key to
accept the new setting. Repeat this process, and enter the correct minutes and
seconds into their respective fields.

7. After the individual hours, minutes, and seconds have been entered into time
setpoint fields, push the SET TIME key to update the CPU with the correct time
setting. (The correct time will appear in the white field on the right hand side of the
screen once the set time key is pressed.)

8. Press the STATUS key to return to the general status window.






Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-6

MANUAL START-UP VS. AUTOMATIC START-UP

Manual start-up requires an operator to physically push the necessary keys in order to
start the compressor and supply air to the plant air system. Automatic start-up requires an
operator to only initiate the panel. The control panel will then automatically start the
compressor and supply air to the plant when the plant air pressure decays to a low level.


MANUALLY INITIATED START-UP

1. Check the oil reservoir level and temperature. If necessary, add oil until the Full
mark is reached on the oil level sight gage. Heat the oil if the temperature is less
than 74F (23C). The optional oil heater should be configured to maintain the oil
temperature at approximately 100F (38 C).

2. Prime the main oil pump if the compressor is being started for the first time, or the
main oil pump has currently been repaired or replaced.

a. Remove the pipe plug from the suction side of the pump.
b. Fill the pump and suction line with oil.
c. Replace and tighten the pipe plug.

3. Turn on the air supply to the pneumatic control components and the seal air piping
harness (if required).

NOTE
Temperature, pressure, and vibration transmitters are
monitored for failure at all times. A fault with any of these
transmitters will be annunciated on the PLC interface and
start-up will be prevented until the fault is corrected.

4. Push the STATUS key on the PLC touch pad screen to access the general status
window. (in the case of initial boot-up, the general status window appears after the
CONTINUE button is pressed on the start-up screen.)

5 Push the MODE key to access the mode of operation screen. The mode of
operation screen contains four individual mode selection menus.

a) CONTROL MODES
b) START/STOP MODE
c) INLET CONTROL DEVICE MODE
d) UNLOADING VALVE MODE

Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-7


FIGURE 3-5
MODE OF OPERATION SCREEN

6. Push the Drop-Down Menu Arrows to access the individual mode selection
menus. Select the desired operating modes by pressing the appropriate selections
within the individual drop-down menus. (The following picture is an example and does
not represent the users specific mode selections.)

FIGURE 3-6
INDIVIDUAL MODE SELECTION SCREEN
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-8

7. After the appropriate control mode selections have been made, push the STATUS
key on the PLC touch pad screen to return to the general status window.

8. Open the cooling water supply valves to the intercooler tube bundles.

9. Pull out the EMERGENCY STOP button on the front of the control panel to enable the
start sequence.

NOTE
If the Emergency Stop button is in the pushed-in position,
the following message will appear in the upper left corner of
the general status window: PULL EMERGENCY STOP TO
ENABLE. If the Emergency Stop button is in the pulled-
out position, the following message will appear in the upper
left corner of the general status window: STOPPED.

10. Push the START function key on the general status window to initiate the start
sequence. A screen will appear prompting the operator to either confirm or cancel the
start sequence. Press the CONFIRM key to continue the start-up procedure.



FIGURE 3-7
REFERENCE - START SEQUENCE


Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-9

NOTE
If the start-up is successful, the following messages will
appear in the upper left corner of the general status screen
throughout the start-sequence:

a) Start Sequence Initiated
b) Drive Starting
c) Driver Accelerating
d) Compressor Running

11. The Auxiliary Oil Pump will start when the start-up procedure is confirmed. Fifteen
seconds after the AOP is started, the low oil pressure alarm and trip are enabled and
the oil temperature is checked. If the oil temperature is 74F (23C) or greater, the
driver is permitted to start. If the oil temperature does not exceed the permissive
setpoint, the following message will appear in the upper left corner of the general
status screen: AOP ON Wait, Cold Oil. If the oil temperature does not exceed 74F
(23C) within 15 minutes, the start-up sequence will be aborted.


FIGURE 3-8
AOP ON WAIT, COLD OIL

CAUTION
Operating personnel should stay clear of the coupling
and rotating shafts while the control system is waiting
for the oil temperature to reach 74F (23C). The driver
will start automatically once the oil temperature reaches
23C (74F).
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-10

12. Twenty-five seconds after the motor starter is energized, the oil pressure is checked,
the motor starter status is checked, and the motor current alarm is enabled. If the oil
pressure is sufficient, the AOP automatically shuts off.

If the oil pressure does not exceed the acceptable level within 60 seconds after the
motor starter being energized, the microprocessor assumes a main oil pump (MOP)
failure and trips the compressor.

If the motor starter status indicates that the driver has not started, the microprocessor
assumes a motor overload condition (etc.) exists, and the start sequence is aborted.

13. Five seconds later, the following events occur:

a) The inlet and unloading valves are placed under control of the PLC. The inlet
control valve modulates from its closed position. The unloading valve waits an
additional 8 seconds to begin modulation to prevent a possible surge.

b) The interstage air temperature alarm and trip are enabled.

OPERATIONAL CHECKS

Although the compressor is designed to operate autonomously, occasional monitoring and
minor adjustment is necessary for safe and efficient operation:

1. Adjust intercooler water valves to maintain the design interstage air temperature 15F
(8C) higher than the design cooling water inlet temperature. The design cooling
water temperature is located on the compressor nameplate.

2. Check the oil reservoir level. Monitor the oil temperature and pressure. If necessary,
adjust water flow through the oil cooler to maintain an oil temperature to the bearings
of 115 - 125F (46 - 52C).

3. The moisture elimination section drain valve discs are notched to allow constant
moisture drainage. In some cases, it may be necessary to open the valves to ensure
adequate drainage.

CAUTION
Ensure that there is no moisture accumulation in the
intercoolers during operation. Plugged or restricted
drainage from the intercoolers will result in a rising
water level and eventual water carry-over into the next
stage of compression. Water in the air stream will
damage impellers resulting in a loss of performance
and vibration.

4. The operating personnel should record data approximately every 4 hours. An
OPERATING RECORD SHEET is provided at the end of this chapter for this
purpose. The operating data should be reviewed periodically. The data will alert the
operating personnel of a maintenance problem, such as a dirty oil cooler, etc. This
will aid the operating personnel in scheduling maintenance shutdowns and reduce
unexpected shutdowns that may be detrimental to the plant.
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-11


AUTOMATICALLY INITIATED START-UP

NOTE
Temperature, pressure, and vibration transmitters are
monitored for failure at all times. A fault with any of these
transmitters will be annunciated on the PLC operator
interface and prevent start-up until the fault is corrected.

1. Check the oil reservoir level and temperature. If necessary, add oil until the Full
mark is reached on the oil level sight gage. Heat the oil if the temperature is less
than 74F (24C). The optional oil heater should be configured to maintain the oil
temperature at approximately 100F (38C).

2. Prime the main oil pump if the compressor is being started for the first time, or the
main oil pump has currently been repaired or replaced.

a) Remove pipe plug from suction side of pump.
b) Fill pump and suction line with oil.
c) Replace and tighten pipe plug.

3. Turn on the air supply to the pneumatic control components and the seal air piping
harness (if required).

4. Push the STATUS key on the PLC touch pad screen to access the general status
window. (In the case of initial boot-up, the general status window appears after the
CONTINUE button is pushed on the start-up screen.)

5. Push the MODE key to access the mode of operation screen.

6. Access the drop-down menu titled START/STOP MODE. Select the desired
operating mode (AUTO/MANUAL or AUTO/AUTO) by pressing the appropriate
selection in the START/STOP MODE drop-down menu. Also, select the desired
control mode (Base, Suction Throttle, Intermittent, or Auto Dual).

NOTE
The (AUTO/MAN) start/stop mode can be selected with any
of the control modes (Suction Throttle, Base Mode,
Intermittent Mode, or Auto/Dual). The (AUTO/AUTO)
start/stop mode can only be utilized when the Intermittent or
Auto/Dual control modes are selected.

Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-12


FIGURE 3-9
CONTROL MODE AND START/STOP MODE SELECTION

7. After the appropriate control mode selections have been made, push the STATUS
key on the PLC touch pad screen to return to the general status window.

8. Open the cooling water supply valves to the intercooler tube bundles.

9. Open the manual block valve to the plant air system.

10. Pull out the EMERGENCY STOP button on the front of the control panel to enable
the start sequence.

NOTE
If the Emergency Stop button is in the pushed-in position,
the following message will appear in the upper left corner of
the general status screen: PULL EMERGENCY STOP TO
ENABLE. f the Emergency Stop button is in the pulled-
out position, the following message will appear in the upper
left corner of the general status screen: STOPPED.

11. Push the START function key on the general status window to initiate the start
sequence. A screen will appear prompting the operator to either confirm or cancel
the start sequence. Press the CONFIRM key to continue the start-up procedure.

Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-13


12. If the system pressure is above the low system pressure setpoint, the unit will be
placed in stand-by mode and the following message will be displayed in the upper left
corner of the general status window: WAITING TO AUTOSTART.


FIGURE 3-10
WAITING TO AUTOSTART


CAUTION
Operating personnel should stay clear of the coupling
and rotating shafts while the control system is waiting
for the plant air pressure to decrease. The driver will
start automatically once the plant air pressure
decreases to the low system pressure setpoint.

13. When the system pressure falls below the automatic start setpoint, the auxiliary oil
pump (AOP) will start.

14. Fifteen seconds after the AOP is started, the low oil pressure alarm and trip are
enabled and the oil temperature is checked. If the oil temperature is 74F (23C) or
greater, the driver is permitted to start. If the oil temperature does not exceed the
permissive setpoint, the following message will appear in the upper left corner of the
general status screen: AOP ON Wait, Cold Oil. If the oil temperature does not
exceed 74F (23C) within 15 minutes, the start-up sequence will be aborted.
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-14



FIGURE 3-11
AOP ON WAIT, COLD OIL


NOTE
The compressor will not autostart if the start-up sequence
has been aborted due to the cold oil condition. The operator
will have to manually launch the start-up sequence, at
which time, the autostart feature will re-initiate.


15. Twenty-five seconds after the motor starter is energized, the oil pressure is checked,
the motor starter status is checked, and the motor current alarm is enabled. If the oil
pressure is sufficient, the AOP automatically shuts off.

If the oil pressure does not exceed the acceptable level within 60 seconds after the
motor starter being energized, the microprocessor assumes a main oil pump (MOP)
failure and trips the compressor.

If the motor starter status indicates that the driver has not started, the microprocessor
assumes a motor overload condition (etc.) exists, and the start sequence is aborted.

Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-15

16. Five seconds later, the following events occur:

a) The inlet and unloading valves are placed under control of the microprocessor.
The inlet control valve modulates from its closed position. The unloading valve
waits an additional 8 seconds to begin modulation to prevent a possible surge.

b) The interstage air temperature alarm and trip are enabled.

SEAL AIR SYSTEM

The seal air system provides pressurized air to the pinion seals. The pressurized air
provides a barrier so that oil cannot leak into the compressed air system. The seal air
system consists of a seal air blow-off regulator and an optional seal air supply regulator.

During normal operation of the air compressor unit, the last stage of compression provides
a small amount of pressurized air into the seal air system. This air is provided to the
pinion seals. The seal air blow-off regulator vents any excess air. The seal air blow-off
regulator should be adjusted to 6-7 psig (0.41 to 0.48 bars).

EMERGENCY SHUTDOWN

1. The compressor will automatically shutdown should any of the following
circumstances occur.

High Final Interstage Air Temperature
Low Oil Pressure
High Vibration Low Speed Pinion
High Vibration High Speed Pinion
Microprocessor Fault
Manual Emergency Trip
Motor Current Transmitter Failure
Oil Pressure Transmitter Failure
Oil Temperature RTD Failure
System Air Pressure Transmitter Failure
Interstage Air Temperature RTD Failure
High Speed Pinion Vibration Transmitter Failure
Low Speed Pinion Vibration Transmitter Failure
Discharge Air Pressure Transmitter Failure

2. When a shutdown command is received the following steps are automatically taken:

a) The driver is shut down.
b) The red trip light will flash and the horn will sound.
c) The auxiliary oil pump will start.
d) The unloading valve will open.
e) The condition that caused the shut down will be displayed in the upper left corner
of the general status window.

3. Once the trip condition is corrected, press the ACKNOWLEDGE key followed by the
RESET key located on the upper left corner of the general status window. These
actions will clear the trip status.


Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-16

FIGURE 3-12
TRIP CONDITION

FIGURE 3-13
COASTDOWN

Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-17


NOTE
The compressor coastdown timer is set for 120 seconds to
prevent an attempted start-up while the driver is coasting
down. A (COASTDOWN) message will appear on the
upper left corner of general status window during the
coastdown period.

4. Two minutes after the shutdown command is received, a compressor restart is
permitted.

5. If a restart is not attempted, the AOP will remain on for an additional thirteen minutes
for cooling purposes and then automatically shut down.

CAUTION
In cold weather climates it may be necessary to
continue running the cooling water to prevent freeze-up
of the oil cooler.

NOTE
The compressor will not auto start if it is shutdown manually
or by an emergency shutdown. The automatic start
sequence must be re-initiated for this mode of operation.

6. Close the shut-off valve if the unit is not going to be restarted.


MANUAL SHUTDOWN

1. Slowly close the manual shut-off valve to isolate the compressor from the plant air
system.
CAUTION
Failure to close the manual shut-off valve may lead to
reverse rotation of the compressor (if the check valve
were to fail).

2. Push the STATUS key on the PLC touch pad screen to access the general status
window.

3. Push the STOP key located on the general status window. A window will appear
prompting the operator to CONFIRM or IGNORE the stop command. Press the
CONFIRM key to continue.

The following actions will take place:

a) The unloading valve slowly opens and the inlet control device slowly closes
unloading the compressor.

b) Approximately 30 seconds later, the driver is shut down.

c) All alarms and trips are disabled.
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-18

d) The compressor coastdown timer initiates. The timer is set for 120 seconds to
prevent an attempted start-up while the driver is coasting down.

e) If the shutdown sequence is successful, the following messages will appear in the
upper left corner of the general status screen throughout the shutdown-sequence:

Stopping
Coastdown
Cooldown
Stopped

NOTE
If the operator encounters an emergency, pushing the
EMERGENCY STOP push button on the front of the control
panel will immediately unload the compressor and shut
down the driver.

4. Two minutes after the shutdown command is received, the message Cooldown
appears in the upper left corner of the general status window, at which time a
compressor restart is permitted.



FIGURE 3-14
COOLDOWN
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-19

5. If a restart is not attempted, the AOP will remain operating for fifteen minutes for
cooling purposes and then automatically shut down.


CAUTION
In cold weather climates it may be necessary to
continue running the cooling water to prevent freeze-up
of the oil cooler.

NOTE
The compressor will not auto start if it is shutdown manually
or by an emergency shutdown. The automatic start
sequence must be re-initiated for this mode of operation.


AUTOMATIC SHUTDOWN

The automatic stop feature is optional.

1. Push the STATUS key on the PLC touch pad screen to access the general status
window.

2. Push the MODE key to access the mode of operation screen.

3. Access the drop-down menu titled START/STOP MODE. Select the desired
operating mode (AUTO/AUTO) by pressing the appropriate selection in the
START/STOP MODE drop-down menu. Also, select the desired control mode
(Intermittent or Auto Dual).

FIGURE 3-15
CONTROL MODES-START/STOP MODE
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-20


NOTE
Steps 1 - 3 are only required for initial start-up.

4. The compressor will now receive an automatic stop command once the plant air
system demand is satisfied.

5. Once the automatic stop command is received, the compressor's inlet control valve
will close and the unloading valve will open.

6. The compressor will continue running in this manner until the system pressure drops
below the low system pressure setpoint at which time the compressor will reload. If
the system pressure does not drop below the low system pressure setpoint within 30
minutes of the compressor unloading, the compressor receives a shutdown
command.

7. When the shutdown command is received the following steps are automatically
taken.

a) The motor starter is de-energized to stop the motor.

b) The auxiliary oil pump will start.

c) The compressor coastdown timer initiates. The timer is set for 120 seconds to
prevent an attempted start-up while the driver is coasting down.

d) If the shutdown sequence is successful, the following messages will appear in
the upper left corner of the general status screen during the shutdown-
sequence:

Stopping
Coastdown
Cooldown
Stopped

8. Two minutes after the shutdown command is received, the message Cooldown
appears in the upper left corner of the general status window, at which time a
compressor restart is permitted. If system pressure has fallen below the low system
pressure setpoint, the compressor will automatically restart.

9. If a restart is not attempted, the AOP will remain on for an additional thirteen minutes
for cooling and then shut down automatically.

10. After coastdown the unit will await an auto start command. The following screen will
be displayed:
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-21


FIGURE 3-16
WAITING TO AUTOSTART

11. When the system pressure drops below the low system pressure setpoint, the
compressor will automatically start.
Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-22

ACKNOWLEDGING ALARMS & TRIPS

Alarms
The alarm action is activated when a monitored parameter has reached an unacceptable
but not critical level of operation. This unacceptable level of operation will be brought to
the attention of the operator via the horn, a yellow flashing common alarm light, and
display on the operator interface.


FIGURE 3-17
GENERAL STATUS SCREEN-PAP RUNNING

1. Push the ACKNOWLEDGE key on the upper left corner of the general status screen.
This will change the yellow common alarm light from a flashing mode to a steady
mode and silence the horn.

2. Push the RESET key on the upper left corner of the general status screen, once the
alarm condition is corrected.

If two or more alarms occur at the same time, the second alarm condition will be
displayed on the general status screen after the first alarm is reset. Likewise, the
third alarm will be displayed after the second alarm is reset and so on up to a
maximum of ten.


Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-23


Trips
The trip function is activated when a monitored parameter has reached a critical and
unsafe level of operation. This critical level of operation will immediately shut down the
compressor, flash the red trip light, sound the horn, and display the parameter that caused
the trip on the upper left corner of the general status screen. To acknowledge the trip:



FIGURE 3-18
GENERAL STATUS SCREEN-TRIP

1. Push the ACKNOWLEDGE key on the upper left corner of the general status screen.
This will change the red common trip light from a flashing mode to a steady on mode
and silence the horn. It will also change the yellow alarm light to a steady on mode.

2. Push the RESET key on the upper left corner of the general status screen once the
trip condition is corrected. The compressor will be ready for restart provided the
coastdown timer has expired.






Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-24

SURGE DETECTION

Surge is a performance characteristic of a compressor that arises when the compressor
cannot overcome the system resistance. When this happens, a flow reversal occurs until
the compressor can again overcome the system resistance. Surge is usually associated
with an excessive discharge pressure, however excessive suction throttling can also
cause surge.

CAUTION
Operating the unit in a surge condition can cause
extensive damage to the compressor. It is
recommended that the unit not be operated in a
continuous surge condition.

If surge occurs while the unit is operated in the suction throttling or dual control modes, the
control system will automatically change the compressor's operating setpoint in an attempt
to prevent future surge occurrences. The control system will also automatically reload the
compressor into the plant air system after making a change to the operating setpoint. If
compressor surge occurs again, the control system will continue to change the operating
setpoint away from surge until a maximum operating setpoint is achieved. At this point,
the unloading valve will remain fully open until an operator investigates the problem and
pushes the ACKNOWLEDGE and RESET function keys.

Surge Detection Check

After the unit is operating, check to see that the surge detection circuitry is functional.

The following procedure may be used:

1. If the block valve to the plant air system is not closed, slowly close it.

2. Push the STATUS key on the PLC touch pad screen to access the general status
window. (In the case of initial boot-up, the general status window appears after the
CONTINUE key is pressed.)

3. Push MODE key to access the mode of operation screen.

4. Access the "CONTROL MODE" drop-down menu.

5. Push BASE to configure the compressor to operate in base mode.

6. Access the "UNLOADING VALVE" drop-down menu.

7. Push MANUAL to place the unloading valve under manual control.

8. Slowly close the unloading control valve by pushing the key. The % open value
on the screen will decrease and the compressor discharge pressure (Fnl Dis XXX
PSIG) will increase. As the discharge pressure increases, the compressor
approaches surge. When surge occurs, the microprocessor should recognize it and
open the unloading control valve, flash the common alarm light, sound the horn, and
display the surge condition on the operator interface screen.
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-25

CAUTION
If the control panel does not recognize surge, push the
key on the operator interface until the surge
condition is eliminated. Contact an Elliott Service
Office.

9. To clear the surge recognition circuit, push the ACK and RESET keys.

10. The unloading control valve can be placed in automatic control by referring to the
MODE section in Chapter 6, UNLOAD VALVE.






























Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-26


NOTES
Chapter 3
Operation
plc chap3 mtr.05/26/2006 3-27


OPERATING RECORD SHEET
PLC Control Panel-English


Customer: Shop Order:
Reported by: Service Order: Date:
Type Of Operation: Base Suction Throttle Intermittent Dual (Circle One)
Abbv Description Units
Date
Time
Fnl Dis Compressor Discharge Pressure (psig)
Oil In Inlet Oil Pressure (psig)
Oil In Inlet Oil Temperature (Deg.F)
HS Vib High Speed Rotor Vibration (M)
LS Vib Low Speed Rotor Vibration (M)
Motor Motor Current (Amps)
Fnl I/S Final Interstage Air Temperature (Deg.F)
U/V PO Unloading Valve Position (% Open)
I/V PO Inlet control device Position (% Open)
Total Run Time (Hours)
PWR ON Panel Power Time (Hours)
Air Sys System Air Pressure (psig)






















Reservoir Oil Level (High/OK/Low


Motor AC (Volts)
Seal Air Pressure (psig)
First Intercooler Drain Operating? (Yes/No)
Second Intercooler Drain Operating ? (Yes/No)


Chapter 3
Operation
plc chap3 mtr.05/26/2006
3-28
NOTES
Chapter 3
Operation
plc chap3 mtr.09/22/2005 3-29
Page ______ of ______
OPERATING RECORD SHEET
PLC Control Panel-Metric



Customer: Shop Order:
Reported by: Service Order: Date:
Type Of Operation: Base Suction Throttle Intermittent Dual (Circle One)
Abbv Description Units
Date
Time
Fnl Dis Compressor Discharge Pressure (BARS)
Oil In Inlet Oil Pressure (BARS)
Oil In Inlet Oil Temperature (Deg.C)
HS Vib High Speed Rotor Vibration (M)
LS Vib Low Speed Rotor Vibration (M)
Motor Motor Current (Amps)
Fnl I/S Final Interstage Air Temperature (Deg.C)
U/V PO Unloading Valve Position (% Open)
I/V PO Inlet control device Position (% Open)
Total Run Time (Hours)
PWR ON Panel Power Time (Hours)
Air Sys System Air Pressure (BARS)


























Reservoir Oil Level (High/OK/Low


Motor AC (Volts)
Seal Air Pressure (BARS)
First Intercooler Drain Operating? (Yes/No)
Second Intercooler Drain Operating ? (Yes/No)
Chapter 3
Operation
3-30 plc chap3 mtr.09/22/2005



NOTES

Chapter 4
Maintenance

P500.ch04.07/02/2007 4-1

INTRODUCTION

This chapter furnishes disassembly, assembly, inspection and adjustment instructions for
the Polaris 500. These instructions must be followed to assure effective repair work and
proper adjustment of components requiring service.

-WARNING-
OBSERVE ALL SAFETY PRECAUTIONS AND
FOLLOW SOUND ENGINEERING PRACTICES
WHEN PERFORMING MAINTENANCE. CLOSE,
LOCK AND TAG ALL AIR SYSTEM ISOLATING
VALVES TO PREVENT THEM FROM BEING
OPENED. ALSO, ENSURE DRIVER AND
AUXILIARIES ARE ISOLATED FROM ALL
UTILITIES TO PREVENT ACCIDENTAL STARTING
DURING MAINTENANCE.

SCHEDULED MAINTENANCE

Scheduled maintenance inspections are necessary for safe and efficient operation. Actual
intervals between inspections are not specified in this manual because maintenance
scheduling is dependent on factors best known by those directly involved with the
Polaris 500 and its particular application. Table 4-1 serves as a general guideline for
establishing a scheduled preventative maintenance program.

Frequency of maintenance inspections can be determined only after careful consideration
of Polaris performance records, maintenance history, corrosion/erosion rates, tests,
observations and anticipated service demands. The established inspection schedule will
usually have to be consistent with the availability of the Polaris, necessary manpower
and an adequate supply of repair parts. At the same time, inspections must be frequent
enough to prevent unsafe operating conditions from developing.

It is also necessary to test and adjust all safety and protective devices, on a regular
schedule, to ensure their reliability. These devices are designed to prevent injury to
personnel and/or major equipment damage. If these devices are not tested at frequent
intervals, they may not work when needed.
Chapter 4
Maintenance
4-2 P500.ch04.07/02/07


TABLE 4-1 SCHEDULED MAINTENANCE GUIDELINES

APPROXIMATE
FREQUENCY

MAINTENANCE DESCRIPTION

REFERENCE
1. Check lubrication system reservoir for proper oil
level.
Chapter 5
2. Check oil system pressures and temperatures.
Install new oil filter cartridge when pressure drop
across filter exceeds 10 psid (0.7 bar differential).
Adjust water flow to oil cooler to maintain design oil
temperature.
Table 5-2
3. Check oil, water and air systems for leaks.
Repair as necessary

4. Check cooling water temperature and air coolers.
Adjust as necessary to maintain design conditions.
Chapter 3
5. Check compressor air temperatures and pressures.
Adjust cooling water flow and controls to maintain
design conditions.
Chapter 3
Chapter 6
6. Observe pressure drop across inlet air filter.
Change primary filter elements if pressure drop
exceeds 5 in. H
2
O (12.7 cm H
2
O) more than
pressure drop across clean filter.

7. Check general condition of control indicators and
monitoring devices.
Replace broken gages, indicator lights, etc.

8. Check overall mechanical operation. Investigate
sudden changes in operating conditions or unusual
noises.
Chapter 3
9. Check pneumatic controls and actuators for air
leaks. Repair as necessary.
Chapter 6
DAILY
10. Check drainage of panel supply air filter. Chapter 2

___________________________________________________________________________
Chapter 4
Maintenance

P500.ch04.07/02/2007 4-3

TABLE 4-1 SCHEDULED MAINTENANCE GUIDELINES

APPROXIMATE
FREQUENCY

MAINTENANCE DESCRIPTION

REFERENCE
1. Start auxiliary oil pump and check operation. Chapter 3
2. Check P of Oil Mist Eliminator. Chapter 5
WEEKLY
3. Inspect Instrument Air Filter (at control panel) for
cleanliness. Replace as needed.



1. Replace secondary inlet air filter.
2. Sample lubricating oil and change oil if necessary. Chapter 5
3. Inspect inlet control device actuator linkage for
excessive play. Repair or replace and adjust as
necessary.
Chapter 6
4. Replace filter element of panel supply air filter. Chapter 2
MONTHLY
5. Replace in-line air filter element of E/P transmitters. Chapter 2

1. Drain lubrication system reservoir and fill with clean oil. Chapter 5 SEMI-
ANNUALLY
2. Operate all Polaris protective devices.
Adjust or replace to ensure their operational reliability
Chapter 6

1. Inspect all bearings for excessive wear. Install new
bearings as necessary and record clearances.
Chapter 4
2. Inspect drive coupling for excessive wear. Repair or
replace and lubricate coupling as necessary.

ANNUALLY
3. Inspect compressor gear and pinions for excessive
wear. Repair or replace worn parts and record
clearances.
Chapter 4
Chapter 4
Maintenance
4-4 P500.ch04.07/02/07


TABLE 4-1 SCHEDULED MAINTENANCE GUIDELINES

APPROXIMATE
FREQUENCY

MAINTENANCE DESCRIPTION

REFERENCE
4. Inspect impellers and diffusers for erosion, corrosion
and/or dirt build-up.
Clean, repair or replace parts as necessary.
Adjust and record impeller running clearances.
Chapter 4
5. Check air/oil seals for excessive wear. Replace if
excessively worn.
Chapter 4
6. Inspect main and auxiliary oil pumps for wear. Repair
or replace worn parts.
Chapter 4
7. Inspect intercooler tube bundles for dirt build-up or tube
leaks. Clean and repair or replace as necessary.
Chapter 4
8. Inspect oil cooler for leaks or scale build-up in tubes.
Clean, repair or replace tube bundle if necessary.
Chapter 4
9. Drain oil and inspect oil reservoir for corrosion or other
contaminants. Clean reservoir and fill with clean oil.
Chapter 5
10Inspect inlet control device, unloading valve and
compressor discharge check valve for proper
operation. Repair or replace worn parts.

11Calibrate gages, control components and protective
devices. Repair or replace defective parts.
Chapter 6
ANNUALLY
(CONTINUED)
12Check condition of electrical connections. Tighten,
clean or remake connections as necessary.



Chapter 4
Maintenance

P500.ch04.07/02/2007 4-5




OIL FILTER CARTRIDGE REPLACEMENT

1. Remove filter canister by threading off of the housing.

2. Replace old canister with a new one.


OIL COOLER

Removal

1. Disconnect oil and water piping.

2. Remove hold down bolts from support brackets.

3. Remove cooler from brackets.

Cleaning

Exterior (oil side) tube surfaces do not normally require cleaning. Several methods can be
used to clean interior (water side) tube surfaces. Many deposits can be removed by
directing a high velocity stream of water through the tubes. In some cases, it may be
necessary to mechanically clean the tube bundle with wire brushes, rods or other specially
designed tube cleaning tools.


Note
Contact the nearest FS-Elliott Company for tube
cleaning details.

Installation

1. Place cooler on support brackets.

2. Install and tighten hold down bolts.

3. Connect oil and water piping.


INTERCOOLERS

The first and second stage intercoolers, if applicable, are integral with the compressor
baseplate. Each intercooler assembly consists of a tube bundle and a moisture elimination
section.

Note
Intercooler water valves have manual flow control.
Chapter 4
Maintenance
4-6 P500.ch04.07/02/07

During manufacture, the interior of the intercooler housing is sand blasted, then coated
with a water resistant phenolic.

Note
If intercooler housing interior surfaces require
recoating, contact the nearest FS-Elliott Company
office for cleaning and recoating specifications.

Tube Bundle Removal

1. Disconnect cooling water piping.

2. Remove cap screws from tube bundle coverplate.

3. Use capscrews in jackscrew holes provided to break flange seal.

4. Withdraw tube bundle from intercooler housing.

Caution
Do not handle tube bundle with hooks or other
devices that might damage tubes or rubber sealing
strips. Use cradles or skids when moving or
handling tube bundles.

Cleaning

Several methods can be used to clean interior (water side) tube surfaces. Many deposits
can be removed by directing a high velocity stream of water through the tubes. In some
cases, it may be necessary to mechanically clean the tube bundle with wire brushes, rods
or other specially designed tube cleaning tools.

Note
Contact the nearest FS-Elliott Company for tube
cleaning details.

Exterior (air side) tube surfaces should be cleaned by water washing.

Caution
Do not use chemical cleaning compounds or
mechanical cleaning methods on the tube bundle
exterior surfaces.

Inspection

Inspect tube bundle for tube leaks or fouling. Clean tube bundle as necessary; plug tubes
or replace tube bundle if leaking.
Chapter 4
Maintenance

P500.ch04.07/02/2007 4-7

Note
It is not practical to replace tubes in tube bundles.
Leaks can usually be stopped by plugging the
defective tube. Compressor efficiency will be greatly
reduced if too many tubes are plugged. For this
reason, FS-Elliott Company recommends replacing the
tube bundle when many tube leaks are evident.

Installation

1. Apply coating of "Silastic" (FS-Elliott part number X427-100) to the tube bundle
cover sealing surfaces.

2. Lubricate the sealing strips with a water-soluble lubricant.

3. Place tube bundle into intercooler housing. Ensure rubber sealing strips are
properly oriented (positioned toward corner radius) to prevent air leakage during
operation.

4. Install cap screws and secure intercooler cover to housing.

5. Connect cooling water piping.


INTERCOOLER DRAIN MUFFLER (if supplied)

The Thru-flow muffler can be used as a very effective means of noise reduction on
intercooler drain lines. The Automuffler should be selected to match the pipe
diameter of the intercooler drain line. The device does have some limitations that
would require additional preparation beyond typical drain line installation. Retrofit to
existing drain lines may not be feasible.

1. The mufflers should be installed vertically downward to prevent condensate
build up inside the muffler.

2. The muffler will allow misting through the sidewall and therefore should be
installed in a drain trough deep enough to accept the muffler body length.

3. The drain trough opening should be wide enough to accept the full diameter
of two mufflers when used with DA3 units.

4. The longevity of the muffler has not been evaluated. Stainless steel version
is available at additional cost.

5. Piping connected to the discharge of the muffler must be the same diameter
or larger. (Preferable there is no piping connected to the discharge.)
Chapter 4
Maintenance
4-8 P500.ch04.07/02/07

6. This device could be used in conjunction with acoustic insulation covering
the drain trough for a highly affective noise reduction installation.

Caution
Inspect the muffler on a periodic basis. Clean or
replace if plugging should occur.


VIBRATION PROBES

Vibration probes are installed in the gear case to monitor pinion vibration. Refer to
Chapter 6 - Control System for replacement and adjustment of the vibration probes.


DISCHARGE CHECK VALVE

Routine examination and maintenance are recommended on an approximate yearly basis.
The soft, resilient seal ring for check valve discs may be inserted by hand on location
when valve is removed from the line. No bonding is required. When a valve is assembled,
the seal ring is locked into position. Only one ring is required. To install seal, separate
body from seal housing, clean ring groove, insert new ring and reassemble valve.

A replacement kit can be ordered from FS-Elliott Company.





Chapter 4
Maintenance

P500.ch04.07/02/2007 4-9

EXTENDED SHUTDOWN

If a compressor is to be shutdown for a period of time greater than a couple of days,
the following steps should be considered to protect the unit against internal corrosion
and damage due to moisture. The greatest need is with units installed outdoors or in
unheated buildings and having outdoor intake. Units installed indoors with air
supplied from inside the building also require protection for extended shutdowns;
however, initiation can usually be delayed from a couple of days to several weeks
without adverse consequences. Clean and complete any maintenance or repair work
on unit prior to preparing for extended shutdown.

Preparation and Maintenance for Extended Shutdown

1. For a motor application: lock out main driver breakers to prevent start-up.
For a turbine application: close section of steam piping from the turbine inlet
and exhaust. Close the inlet steam and exhaust valve to the turbine.

2. Remove section of air piping from the compressor discharge.

A. If a motor application: connect a warm, dry, low-pressure air source to the
compressor discharge. If a turbine applications: connect a warm, dry low-
pressure air source to the compressor discharge and the turbine inlet.
Circulate warm, dry air through the units for at least 24 hours.

B. Record the inlet and discharge air temperature and relative humidity hourly.
Continue air circulation for 6 hours after the discharge air has essentially
same moisture content as the inlet air. Intercoolers and other low points are
the primary source of moisture. Good preservation practice requires all
liquid to be eliminated from unit's internals, and the moisture content
reduced to the lowest possible level.

Note
Air heated to approximately 150F (66C) will greatly
speed up the moisture removal process.

3. When the units are dry, remove the temporary air source. Blank off the
compressor inlet and discharge with steel covers and gaskets. Blank off the
turbine inlet and exhaust with steel covers and gaskets. A bag of desiccant
(MIL D-3464 or equivalent) should be attached to the inside of the steel
covers on compressor and if applicable, the turbine.

4. Plug the intercooler drains with steel plugs. Remove the oil mist eliminator
and plug. Wrap the oil reservoir vent nozzle with waterproof tape. Remove
water piping to intercoolers, oil coolers, and aftercoolers. Drain water and
blow dry. Remove the buffer seal relief valve and install a cap. Plug
openings with steel plugs.

5. For a turbine application: supply a nitrogen bottle arrangement to the steel
inlet blind flange and continuously purge the turbine with nitrogen at a 1 - 2
scfm flow.
Chapter 4
Maintenance
4-10 P500.ch04.07/02/07


6. Supply a nitrogen bottle arrangement to the buffer seal header on the
compressor and pressurize to 15 psi (1.0 bar). Check and repair any leaks.

Note
An alternative is to use a pressure regulator, timer, and
solenoid arrangement to supply nitrogen to the buffer
seal header for 15 seconds every eight hours. This will
reduce the amount of nitrogen used and provide
adequate corrosion protection.

7. Place a 100-watt light bulb or strip heater in the control panel and energize.

8. The preferred arrangement is to warm the oil and circulate the oil each week
using the auxiliary oil pump. During this period, turn the compressor and
turbine two or three revolutions using a strap wrench to assure oil coverage
of the gearing and bearings.

Caution
Do not run the auxiliary oil pump more than five
minutes. Excessive running time may cause oil to
migrate across the seals.

9. Check nitrogen pressure weekly.

10. Recommendations for the extended shutdown and storage of the driver are
provided in the Drivers Instruction Manual. (Motor-Chapter 8 Accessories;
Turbine: Turbine Instruction Manual)

Preparation for Re-Start After an Extended Shutdown

1. Disconnect nitrogen system and re-install buffer seal relief valve.

2. Re-install oil mist eliminator.

3. Reconnect water piping and intercooler drain piping. Remove plugs from the
intercooler drains.

4. De-energize the space heaters and/or light bulbs. Remove any light bulbs.

5. Remove desiccant and reconnect inlet and discharge lines.

6. As a precaution, remove casing drain and check for any liquid. Contact the
nearest FS-Elliott Company location if assistance in required.

7. Re-grease coupling (if applicable), change oil filters and check oil levels of
compressor and turbine. Stroke the inlet and unloading control valves (open
and closed) to assure proper operation.

8. Take an oil sample and check the moisture content. Change oil if
necessary.
Chapter 4
Maintenance

P500.ch04.07/02/2007 4-11



9. Guidelines on the preparation for service of the motor and turbine are
provided in the Drivers Instruction Manual. (Motor-Chapter 8 Accessories;
Turbine: Turbine Instruction Manual)

10. For a motor application: reconnect main motor breakers. For a turbine
application: reconnect the steam piping to and from the turbine inlet and
exhaust.

11. Follow the start-up procedures as outlined in Chapter 3 - Operation.
Chapter 4
Maintenance
4-12 P500.ch04.07/02/07


NOTES
Chapter 4
Maintenance

P500.ch04.07/02/2007 4-13

Extended Shutdown Checklist

SHUTDOWN PERIOD FROM ____________ TO ____________


I. PREPARATION FOR SHUTDOWN

1A. __________ FOR MAIN MOTOR: LOCK OUT MAIN MOTOR BREAKER.

1B. __________ FOR TURBINE: CLOSE STEAM PIPING TO AND FROM TURBINE.

2. __________ BLOW DOWN COMPRESSOR WITH WARM, DRY AIR.

3. __________ REMOVE AIR PIPING, BLANK OFF AND ATTACH DESICCANT.

4. __________ REMOVE WATER PIPING TO ALL COOLERS, DRY AND PLUG.

5. __________ PLUG INTERCOOLER DRAINS.

6. __________ REMOVE BUFFER SEAL RELIEF VALVE AND CAP.

7. __________ REMOVE OIL MIST ELIMINATOR AND PLUG PIPE.

8. __________ PRESSURIZE AND BLEED NITROGEN PURGE.

9. __________ MAIN MOTOR ONLY: ENERGIZE THE MAIN MOTOR SPACE HEATERS

10. __________ DISCONNECT PNEUMATIC LINES TO CONTROL PANEL.

11. __________ SUPPLY LIGHT BULBS OR STRIP HEATERS.

12. __________ FOLLOW RECOMMENDATIONS IN DRIVERS INSTRUCTION MANUAL
MAIN MOTOR: CHAPTER 8 - ACCESSORIES
TURBINE: TURBINE INSTRUCTION MANUAL

II. MAINTENANCE DURING SHUTDOWN

Follow
Heat & Rotate Check N
2
Driver Personnels
Circulate Compressor Supply Recommendations Initials Remarks
____________________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

Chapter 4
Maintenance
4-14 P500.ch04.07/02/07

Extended Shutdown Checklist


Follow
Heat & Rotate Check N
2
Driver Personnels
Circulate Compressor Supply Recommendations Initials Remarks
____________________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________

WEEK OF___________________________________________________________________________



Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007

5-1


INTRODUCTION

This chapter furnishes operating data, lubricant requirements and pre-start inspection and
preparation procedures for the Polaris lubrication system. A functional description of major
system components is also furnished.

The type of driver, operational and environmental conditions at the installation site, or
individual preferences in the selection of system components determine the design of the
lubrication system. Operators should become familiar with the components described in this
chapter, the P & I Diagram (or the Lubrication Schematic), and Oil Piping Drawing located in
Chapter 10-Technical Drawings. Operators must have a complete understanding of the
lubrication system to operate and maintain it, and/or to take proper corrective action in an
emergency.


LUBRICATION SYSTEM COMPONENTS


Oil Reservoir
The oil reservoir is located in the Polaris baseplate. The reservoir is equipped with a filler
opening, a drain connection, a covered access for internal inspection and cleaning, an oil level
sight gage and a vent with an oil mist eliminator.


Pumps and Drivers
The lubrication system has two positive displacement, rotary pumps. These pumps provide a
constant oil flow to the compressor bearings and gears. The main oil pump is driven by the
gear shaft. The motor driven auxiliary oil pump, located in the oil reservoir, operates
automatically when starting and stopping the Polaris or when the oil pressure is low.

Both pumps supply oil at a flow rate and discharge pressure in excess of that required for
normal operation. This excess capacity ensures a pressure controlled oil flow during all
operating conditions. A relief valve in the gearcase maintains design oil pressure to
compressor bearings and gears.
Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007
5-2


Oil Cooler
The oil cooler is a shell and finned tube type heat exchanger. Cooling water flows through the
tubes. Oil flows through the shell and around the tubes. Baffles inside the shell control the oil
flow through the cooler.


Oil Mist Eliminator
The oil mist eliminator is used to vent air from the gear case and reservoir. Oil entrapped in
the air is separated by a coalescing filter and returned to the reservoir. The filter element in
the oil mist eliminator should be replaced when the P reading (on the Oil Mist Eliminator
gauge) across the element exceeds 10" H
2
0.


Oil Filter
A canister type oil filter is used in the Polaris lubrication system. The filter has vents for air
removal and a gage is installed on the inlet port to monitor the pressure drop across the filter.
New filter canisters must be installed when the pressure differential reaches a reading greater
than 10 psid (0.7 bar) of the clean pressure drop reading. Refer to the Control Panel
Configuration Sheets located in the Equipment Data section of this manual to determine the
pressure differential setpoint. Once the pressure differential reaches this setpoint, a new filter
canister should be installed.

An optional dual filter with an integral transfer valve is available. The dual filter is a cartridge
type.


Thermostatic Mixing Valve
A thermostatic mixing valve is furnished to regulate the oil temperature to the compressor.
When the oil temperature to the compressor is below 110 F (43 C), the mixing valve causes
the oil to bypass the oil cooler. When the oil temperature exceeds 120 F (49 C), the mixing
valve routes all the oil through the cooler. At oil temperatures between 110 F and 120 F (43
C and 49 C), the mixing valve regulates the oil flow between the oil cooler and the bypass to
maintain this temperature range.

Oil Heater and Low Oil Level Switch
An oil heater and low oil level switch is provided as optional equipment. The heater is
installed in the side of the oil reservoir. An integral thermostat can be adjusted to obtain the
desired oil temperature. Should the oil level fall below the heating elements, the oil level
switch will sense it and automatically de-energize the heater. Power can be restored after the
oil level is increased.

Relief Valve
The oil system relief valve is used to maintain 25 psig of oil pressure in the gearcase header.
The oil pressure can be adjusted while the unit is running by removing the cap on the relief
valve and turning the adjusting screw clockwise (CW) to raise the pressure and
counterclockwise (CCW) to lower the pressure. After the pressure is set, tighten the locknut to
keep the adjusting screw in position.




Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007

5-3
Piping
The lubrication system components are joined together by the necessary piping to make the
system functional. This includes provisions for installing monitoring, control and safety
devices.

Safety, Control and Monitoring Devices
The lubrication system is equipped with an oil pressure transmitter and an oil temperature
transmitter on the oil feed line to the compressor. These devices are located on the unit and
are wired back to the control panel. The oil pressure transmitter trips the compressor if a low
oil pressure condition should occur. The oil temperature transmitter alarms and trips the
compressor if a hot oil condition should occur.

During normal compressor operation, the main oil pump supplies oil to fulfill the unit's oil
requirements (bearings and gears). The auxiliary oil pump remains on standby in case the
performance of the main oil pump deteriorates. The relief valve should be adjusted to
maintain a system oil pressure within the range of 25 psig (1.7 bar) to 30 psig (2.0 bar). A
sufficient system oil pressure of 25 psig (1.7 bar) minimum must exist at all times during
compressor operation. Should the system oil pressure decrease to 15 psig (1.0 bar), the unit
will automatically shutdown.


When the unit shuts down, (manually or due to a safety trip device), the auxiliary oil pump
automatically starts. The auxiliary oil pump continues to operate and cool the compressor
bearings. After 15 minutes, the auxiliary oil pump automatically shuts off.

Caution
A Low Pressure trip is an indication that the
compressor is not receiving adequate lubrication. In
this situation, an operator must investigate and correct
the root cause of the problem. Contact your local FS-
Elliott Service Office, if necessary. Otherwise, severe
mechanical damage to the compressor may occur.


Differential Oil Pressure Alarm (Optional)
This feature provides an alarm if the differential pressure across the oil filter/system exceeds
the setpoint. This feature is optional and may not apply to the unit ordered. Refer to the
Control Panel Configuration Sheet located in the Equipment Data Section of this manual to
determine the setpoints. A differential switch senses the differential oil pressure and sends a
signal to the control panel.

Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007
5-4

OIL REQUIREMENTS

For optimum operation and extended service life, FS-Elliott recommends the use of Corona
Turbo Blue
TM
lubricant. This premium lubricant is specifically blended for use in the Polaris
Compressor and will provide the following benefits:

Extended lubricant life
Minimizes build-up of lacquer, varnish or resins
Excellent wear protection
Superior resistance to foaming
Longer equipment operating cycles
Reduced down time
Free oil analysis program

Corona Turbo Blue
TM
is a premium blend of synthetic and petroleum base fluids specially
designed for centrifugal compressor applications. This lubricant is manufactured using state-
of-the-art refining technology and utilizes only the highest quality base feedstocks with
premium additives. These meticulously selected additives include superior rust and corrosion
inhibitors, oxidation control agents, anti-wear compounds and defoamants and is exceptional
at controlling sludge and deposits.

Corona Turbo Blue
TM
lubricant is supplied with all new FS-Elliott centrifugal compressors. Any
additions, substitution or mixing of lubricant brands is not recommended and could potentially
result in mechanical damage and/or poor performance. However, if the user elects to
substitute a lubricant, Tables 5-1 and 5-2 contain information to assist in selecting the proper
lubricant. USAGE OF UNSPECIFIED LUBRICANTS IS DONE AT THE OWNERS RISK.
Corona Turbo Blue
TM
meets or exceeds all of the parameters noted in these tables.

Making the proper lubricant selection is the first step to ensuring long-term reliable operation.
It is essential to maintain the lubricant in the best possible condition. Contamination by water,
dust, chemicals or other impurities must be prevented. Establishing an analysis discipline to
determine the frequency of lubricant changes is a key element of any long-term oil
management program. FS-Elliott can recommend a procedure for sampling and testing.
Sampling kits including mailing boxes are available from your local FS-Elliott distributor.

WARNING
THIS UNIT IS SUPPLIED WITH CORONA BRAND
LUBRICANT. MIXING LUBRICANTS COULD DILUTE
THE ORIGINAL FLUID AND CAUSE ADVERSE EFFECTS
TO THE OPERATION OF THE COMPRESSOR AND THE
LUBRICATED COMPONENTS. FS-ELLIOTTS CORONA
BRAND LUBRICANT IS FACTORY RECOMMENDED
AND ENGINEERED FOR USE IN THIS COMPRESSOR.
USE OF OTHER TYPES OF LUBRICANT MAY RESULT
IN LOSS OF WARRANTY.

For detailed information and availability of Corona Turbo Blue
TM
, contact the nearest FS-Elliott
Company representative. To locate a representative for your region, go to website address:
http://www.fs-elliott.com

Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007

5-5

PREPARING FOR INITIAL OPERATION

The lubrication system is cleaned, flushed and tested before the Polaris is shipped. After
the factory testing is completed, the oil system is drained and the reservoir is re-filled with new
Corona Turbo Blue
TM
lubricant and a new oil filter canister is installed. However, the system
must be inspected for contamination or damage that may have occurred during shipment or
storage before the Polaris is placed in service.

Review the Lubrication System Flushing section of this chapter for instances where the
system is being changed from a mineral base or other type lubricant to Corona Turbo Blue
TM
.

LUBRICATION SYSTEM FLUSHING

Maintaining a clean, sludge free supply of a premium lubricant is essential to providing smooth
equipment operation and maximum service life.

As noted previously, all new FS-Elliott centrifugal compressors are supplied with Corona
Turbo Blue
TM
lubricant. ANY OTHER TYPE OIL ADDITIONS, SUBSTUTUTIONS OR MIXING
OF LUBRICANTS IS NOT RECOMMENDED. Contact your local FS-Elliott representative if
there are any questions or doubt concerning the type of lubricant presently being utilized.
Your local FS-Elliott representative can provide a lubricant sampling kit and follow-up analysis
service to determine the condition and type of lubricant contained in the reservoir. In the
event that the compressor has been operating for a period of greater than thirty days and is
being converted to Corona Turbo Blue
TM
lubricant, or if oil analysis indicates that the system
has been contaminated, the lubrication system should be flushed to remove lacquer, varnish,
resins, and other harmful material that may have entered the oil supply.
Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007
5-6


Flushing Procedure
This section provides a procedure for the replacement of petroleum (mineral) oil in the FS-
Elliott compressor to the Corona Turbo Blue
TM
lubricant. This procedure ensures trouble-free
operation of the FS-Elliott compressor. The following tools are required: empty oil drums
according to oil reservoir capacity, a hand or motorized pump, a dolly or fork truck and oil dry
or other absorbent material.

Varnish/carbon deposits can form when an over-extended petroleum based (mineral) oil is
being utilized. To ensure that these deposits are removed from the system, FS-Elliott
engineers have developed a cleansing process for use with the specially formulated fluid
Corona Turbo Clean
TM
.

This flushing procedure was developed exclusively for FS-Elliotts Polaris lubrication system
and eliminates the need to disassemble the compressor for cleaning. This procedure is
recommended for any compressor that has been operated for more than 30 days and is being
converted over to Corona Turbo Blue
TM
.

1. A ratio of 1 gallon of Corona Turbo Clean
TM
is required for every 10 gallons of mineral
oil in the oil reservoir. Refer to Table 5-2 for the capacity of the oil reservoir. Some of
the oil must be removed from the reservoir before any Corona Turbo Clean
TM
is applied
to the system. This can be completed while the unit is in operation provided care is
taken not to lower the oil level below the safe minimum operating level.

2. Once the Corona Turbo Clean
TM
is placed into the reservoir, continue to operate the
compressor for a minimum of 40 hours.

Caution
The unit should not exceed 60 hours of operation
during the cleansing period.

3. After running the compressor for the required 40 to 60 hours, shutdown the
compressor and drain the old lubricant from the system while it is still hot. The oil must
be drained while hot to prevent any contaminants from settling out of the system. To
ensure that all the oil is removed, the piping must be disconnected at any low points in
the lubrication system. Refer to the oil piping drawings in Chapter 10-Technical
Drawings. Connect a drain line to the oil reservoir drain and pump the old lubricant out
of the reservoir and into a container.

4. Once all of the oil is drained from the system, the oil reservoir cover must be removed.
Using lint free rags, any remaining oil in the reservoir must be cleaned/removed from
the reservoir. Any spilled oil should be cleaned up using oil dry or any other oil
absorbent.

5. The oil filter(s) must be replaced and the housing cleaned.

6. Once the oil system is drained, all the oil piping connections must be re-connected.
The oil reservoir should be filled to the proper level with Corona Turbo Blue
TM
. Refer to
the Table 5-2.
Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007

5-7

7. Corona Turbo Blue
TM
and Corona Turbo Clean
TM
are compatible with mineral oil, in
that, no special requirements or procedures are needed for disposal. The standard
lubricant disposal practices should be used for disposal of the used lubricant and
lubricant filter.

8. Prime the main oil pump prior to re-commissioning the compressor.

9. Circulate the oil through the system using the auxiliary oil pump for 15 minutes. While
operating the auxiliary oil pump, ensure that 4 to 6 psig (.28 to .41 bar) seal air
pressure is available. Otherwise, oil migration across the seals could occur. (Refer to
Chapter 6-Controls for instructions on how to place the Auxiliary Oil Pump in
circulate/test mode).

10. Inspect the oil piping to ensure that there are no lubrication leaks. Any leaks must be
corrected before start-up.

11. Follow the standard start-up procedure for the compressor. Refer to Chapter 3-
Operation for start-up instructions.


Prior to Start-Up

1. Start the auxiliary oil pump. Refer to "Manual Operation of Auxiliary Oil Pump" as
outlined in Chapter 6. Circulate oil for approximately 15 minutes.

Caution
If the auxiliary oil pump starts but oil pressure is not
obtained, the pump is probably rotating in the wrong
direction. Immediately shut down the pump and
interchange any two of the three power leads to the
control panel.

2. Check operation of all gages and thermometers, and inspect oil piping for leaks.

Note
Make all pressure-setting adjustments with oil at normal
operating temperature.
Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007
5-8


TABLE 5-l
GUIDELINES FOR SELECTING LUBRICATING OILS
(Mineral, Synthetic, or Blended Synthetic)

RECOMMENDED VISCOSITY (SUS @ l00F)

145 - 165

RECOMMENDED VISCOSITY (SUS @ 2l0F)

43 - 46

RECOMMENDED VISCOSITY (cSt @ 40C)

27.8 32.0

RECOMMENDED VISCOSITY (cSt @ 100C)

5.0 6.0

VISCOSITY INDEX

Above 90

MINIMUM FLASH POINT

350F / l75C

Note
Figures given in this table indicate general service
requirements for FS Elliott compressors. Specific
lubricating oil recommendations are left to the oil supplier.
Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007

5-9


TABLE 5-2
LUBRICATION SYSTEM CONTROL PANEL OPERATING DATA
ISO Grade 32
Low Oil Temperature Alarm

70
o
F 21
o
C
Minimum Oil Temperature for
Permissive Start

74
o
F 23
o
C
System Oil Pressure
(Measured at Header Gauge)
25 psig
to
30 psig
1.7 bar gage
to
2.1 bar gage
Maximum Pressure Drop Across
Oil Filter
10 psid 0.7 bar differential
(When the pressure differential reaches a reading greater than 10 psid (0.7 bar) of the clean pressure drop reading,
the oil filter canister should be changed. The figure listed on the Control Panel Configuration Sheet indicates the total
oil Filter pressure Drop for the alarm indication).
Low Oil Pressure Trip

15 psig
Decreasing
1.0 bar gage
Pressure
Low Oil Pressure Permissive 21 psig
Increasing
1.4 bar gage
Pressure
Auxiliary Oil Pump
Start Pressure
20 psig
Decreasing
1.4 bar gage
Pressure
Auxiliary Oil Pump
Stop Pressure
37 psig
Increasing
2.5 bar gage
Pressure
Oil Temperature
From Oil Cooler
115
o
F
to
125
o
F
46
o
C
to
52
o
C
High Temperature Alarm Oil
From Cooler
135
o
F
Increasing
57
o
C
Temperature
High Temperature Trip Oil
From Cooler
140
o
F
Increasing
60
o
C
Temperature

Reservoir Capacity

65 Gallons

245 Liters


Chapter 5
Lubrication
P500.chap05.turbo-blue.7/02/2007
5-10

NOTES







Chapter 6
Control System
PLC.ch06 10in.08/04/2006 6-1


INTRODUCTION

This section describes the operation of the PLC control system, the functions of the control
components, and provides adjustment procedures for compressor setpoints, control
components, and compressor protective devices.


PRINCIPLE OF OPERATION

The PAP PLC control system regulates the inlet and unloading valves, monitors the
operating parameters (temperatures, pressures, etc.), provides alarm and trip indications,
sequences the start-up and shutdown of the unit, governs the different modes of
operation, stores pertinent data, and provides hard-copy output of information via serial
printer interface, and communicates with remote devices (optional).

The control panel utilizes a PLC to perform these functions. Integral with the PLC is the
HMI LC Touch panel display. The Touch panel is equipped with a 10.4 display, 256
colors, 640 X 480 pixels. On the side of the HMI display is a slot for the CF (Compact
Flash) card that is used to store up to 2400 sets of Historical data.

The I/O may vary based on which configuration the customer purchases. There are three
possible configurations. Base, Industrial, and Engineered. A Base or Industrial panel may
utilize a smaller 5.7 display and the screen selections may slightly differ from the 10.4
display as shown throughout this document.


Base Configuration
Contains two (2) RTD direct analog inputs for temperature measurement. The remaining
six (6) are 4 - 20 mA inputs sourced by transmitters. The 2 analog outputs are 4-20 ma I/P
transmitters used to drive the inlet and unloading valves. There are 8 discrete inputs and
8 discrete outputs. Local printer ports are located on the underneath side of the HMI
display inside the panel for serial transmission. The USB port provides Print Screen
Captures providing the customer has a USB printer.


Industrial Configuration
The Industrial Configuration has several selections to choose from. The amount of analog
inputs may vary depending upon what package the customer has purchased. The analog
outputs remain the same. The amount of digital Inputs and outputs may also change.

Package A Filter Monitoring (AFDP,OFDP)
Package B Air Sensing (FIT,ACT)
Package C Motor Stator (SMT1)
Package D Driver Bearing (IMT,OMT)
Package E Turbine Driver (DST,IPT,ATT)
Package F Driver Vibration (IDTX,ODTX)
Package G User Defined (UDT1,UDT2)


Chapter 6
Control System
PLC.ch06 10in.08/04/2006
6-2


Engineered Configuration
In the Engineered Configuration, the customer is given a selection of additional pressure
inputs, RTD direct inputs, and vibration inputs.

Pressure Inputs (MOPT,OPTT, WPT)
RTD Inputs (SMT2,SMT3,HOT,BOT,LOT,DTT,ORT,WTT,IATT,IOTT
Vibration Inputs (LVTY,HVTY,IDTY,ODTY,AXL)


Primary communication with the PLC is through the integral HMI Touch Screen display on
the front of the control panel. Commands for starting the compressor, selecting control
modes, entering setpoints, acknowledging alarms, etc. are entered on the Touch Screen.
The display informs the operator of the unit's operating status, setpoints, data, control
modes, and alarm and trip conditions. Additional communication with the PLC can be
accomplished from a remote HMI Display or remote host computer by way of
communications ports.

The inlet control valve/guide vanes are positioned to maintain a desired motor amperage.
The unloading control valve is responsible for maintaining the desired discharge pressure.
The unloading valve opens to exhaust compressed air to atmosphere when the
compressor output flow exceeds the system demand. The valves (or guide vanes) may be
positioned manually or automatically through the PLC interface. Refer to the Mode section
in this chapter for these instructions.

Power-Up of Control Panel
When power is applied to the control panel, the microprocessor and display screen go
through a boot-up process.

The touch screen display on the front of the control panel is operated by the Microsoft
Win CE software package. Win CE writes data into files on the Compact Flash storage
card for the historical archive. If power was removed from the control panel, while Win CE
was writing to the files, the data file on the Compact Flash card becomes corrupt. When
power is reapplied to the control panel, Win CE detects that the writing process was not
completed and will display an error message on the display screen. This error message is
shown below.



This condition has no adverse effects on the control panel. The Compact Flash storage
card is not damaged and the control system automatically repairs the file on the Compact
Flash storage card during power-up of the control panel. Simply press the Yes button to
correct the error and clear the error message. The display screen will continue with the
boot-up process and will function properly.

Chapter 6
Control System
PLC.ch06 10in.08/04/2006 6-3

OPERATOR INTERFACE

The front of the control panel contains a Touch panel display known as the operator
interface. The display is a Liquid Crystal Touch Screen. Through this device the operator
can communicate with the PLCs programming architecture. Refer to Figure 6-1.

The contrast level of the touch panel display can be adjusted by pressing the UTLILTY
button and then pushing either the CONTRAST (+) or CONTRAST (-) buttons. Pressing
the Contrast (+) button will make the touchpad display darker, and the Contrast (-) button
will make the touchpad display brighter.

The programming architecture is keyed-in via the General Status Screen. This screen
provides headings for various avenues of information retrieval. To access the General
Status Screen push the STATUS key on the touch panel display. The screen, which is
shown in Figure 6-1, will appear on the touch panel display. Push the desired heading to
access the corresponding screens. A description of each heading is given on the below
and on the following page.


FIGURE 6-1
GENERAL STATUS SCREEN
Chapter 6
Control System
PLC.ch06 10in.08/04/2006
6-4

1 - STATUS

When this heading is selected, the PLC touch panel will display the general status
screen (Figure 6-1). The general status screen is the default screen for the PLC control
system. This screen will appear upon initial boot-up of the PLC control system and
displays crucial operating parameters, as well as, the operating status of the compressor
(the operating status can be reviewed in Chapter 3 of this instruction manual). The actual
status heading will not appear when viewing this screen, however, if the user has
accessed any other menu, the status heading will appear giving the user the ability to
return to the general status screen at any time.

NOTE:
If the compressor experiences an alarm or trip
condition, the PLC touch pad display will automatically
revert to the general status screen by default.

The following figures depict various operating status messages that will appear in the
upper left corner of the general status screen.



FIGURE 6-2
GENERAL STATUS SCREEN (Pull Emergency Stop To Enable)



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Referencing Figure 6-2, the message Pull Emergency Stop to Enable is displayed in the
upper left corner of the general status screen. This message indicates that the emergency
stop/start button (located on the front of the control panel) is in the disabled position. It is
necessary to change the emergency stop/start button to the pulled-out position to permit
start-up of the air compressor. The Pull Emergency Stop to Enable message will be
replaced with a ** PAP SHUTDOWN ** message if the emergency stop/start button is
changed to the pulled-out position (the compressor can now be started).


FIGURE 6-3
GENERAL STATUS SCREEN (Waiting To Autostart)

Referencing Figure 6-3, the message Waiting to Autostart appears in the left hand corner
of the general status screen. This optional screen indicates that the PLC is in the auto
start mode awaiting the auto start signal based on system air pressure.

FIGURE 6-4
GENERAL STATUS SCREEN (Stopped)

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Referencing Figure 6-4, the message Confirm Start or Cancel appears in the center of
the general status screen. This message will appear when the user has initiated a start
sequence by pressing the Start heading. The user then has the option to continue the
start sequence or cancel the sequence aborting start-up. The selection window will
disappear after 10 seconds if the operator does not make a selection.

FIGURE 6-5
GENERAL STATUS SCREEN (Drive Accelerating)

Referencing Figure 6-5, this screen appears during acceleration of the driver after a start
sequence is initiated.
FIGURE 6-6
GENERAL STATUS SCREEN (PAP Unloaded)

Referencing Figure 6-6, this optional screen will appear when the compressor receives an
auto stop signal in certain control modes.
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FIGURE 6-7
GENERAL STATUS SCREEN (Coastdown)

Referencing Figure 6-7, the message Coastdown is displayed in the upper left corner of
the general status screen. This message is displayed any time the driver shuts down.
Restart of the compressor is prevented until the coastdown timer expires.












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2 - SETPT

There are five individual setpoint screens on the PLC control system. These setpoint
screens will display various operating parameters along with tuning constants for surge
detection, PI control, historical scan time, and adaptive increment control. The following
procedure is used for examining and changing these setpoints.

CAUTION
Changing the compressor setpoints can cause
compressor surge and/or bypass the protective devices.
Changing the compressor setpoints can result in severe
mechanical damage.

SETPOINT SCREEN 1

1. Push the SETPTS heading located on the general status screen to access
Setpoint Screen 1.


FIGURE 6-8
SETPOINT SCREEN 1
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2. Referencing Figure 6-8, setpoint screen 1 displays four adjustable setpoints (these
individual setpoints will be described later on in this chapter). To change a setpoint,
press the appropriate field where the current sepoint value is displayed, and a
numeric keypad will appear. Key in the desired numeric value, then press the key
to accept the new value (the level 1 password will be required to change setpoints).


SETPOINT SCREEN 2

1. Push the SETPTS heading located on the general status screen to access
Setpoint Screen 1.

2. Push the SETPT.2 heading that is located on setpoint screen 1 (reference Figure 6-
8).


FIGURE 6-9
SETPOINT SCREEN 2

3. Referencing figure 6-9, setpoint screen 2 displays six adjustable setpoints (these
individual setpoints will be described later on in this chapter). To change a setpoint,
press the appropriate field where the current setpoint value is displayed, and a
numeric keypad will appear. Key in the desired numeric value, then press the key
to accept the new value (the level 1 password will be required to change setpoints).

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SETPOINT SCREEN 3

1. Push the SETPTS heading located on the general status screen to access
Setpoint Screen 1.

2. Push the SETPT.3 heading that is located on setpoint screen 1 (reference Figure 6-
8).



FIGURE 6-10
SETPOINT SCREEN 3

3. Referencing Figure 6-10, setpoint screen 3 displays three adjustable setpoints (these
individual setpoints will be described later on in this chapter). To change a setpoint,
press the appropriate field where the current setpoint value is displayed, and a
numeric keypad will appear. Key in the desired numeric value, then press the key
to accept the new value (the level 1 password will be required to change setpoints).





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SETPOINT SCREEN 4

1. Push the SETPTS heading located on the general status screen to access
Setpoint Screen 1.

2. Push the SETPT.4 heading that is located on setpoint screen 1 (reference Figure 6-
8).


FIGURE 6-11
SETPOINT SCREEN 4

3. Referencing Figure 6-11, setpoint screen 4 displays five adjustable setpoints (these
individual setpoints will be described later on in this chapter). To change a setpoint,
press the appropriate field where the current setpoint value is displayed, and a
numeric keypad will appear. Key in the desired numeric value, then press the key
to accept the new value (the level 1 password will be required to change setpoints).







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SETPOINT SCREEN 5

1. Push the SETPTS heading located on the general status screen to access
Setpoint Screen 1.

2. Push the SETPT.5 heading that is located on setpoint screen 1 (reference Figure 6-
8).


FIGURE 6-12
SETPOINT SCREEN 5

3. Referencing Figure 6-12, setpoint screen 4 displays four adjustable setpoints and the
current date and time settings (the setpoints will be described later on in this chapter).

a) To change a setpoint, press the appropriate field where the current setpoint value
is displayed, and a numeric keypad will appear. Key in the desired numeric value,
then press the key to accept the new value.

b) To change the current date, push the month setpoint field and a keypad will
appear. Enter the correct month on the keypad then push the key to accept the
new setting. Repeat this process, and enter the correct day and year into their
respective fields.

c) To set the correct time, push the setpoint field that represents the current hour
and a keypad will appear. Enter the correct hour on the keypad then push the
key to accept the new setting. Repeat this process, and enter the correct
minutes and seconds into their respective fields.

d) After the individual hours, minutes, and seconds have been entered into time
setpoint fields, push the SET TIME key to update the CPU with the correct time
setting (The correct time will appear in the white field on the right hand side of the
screen once the set time key is pressed).
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SETPOINTS

Listed below are the various setpoints found on the PLC setpoint screens. Some of the
setpoints are optional and will not apply to every user. Refer to the PLC Configuration
sheet located in the Equipment Data section to determine which setpoints apply to your air
compressor unit. This Configuration sheet also lists the design setpoint values.

Discharge Air Pressure SetPt. - The PLC control system utilizes the unloading valve to
maintain this pressure at the discharge of the air compressor.

System Air Pressure Low SetPt. - This setpoint determines the plant air pressure at which
the unit loads and/or automatically starts.

Minimum Motor Amps SetPt. - This setpoint (along with the Maximum Motor Amps
setpoint) determines the operating amperage range of the driver (motor). The MIN amps
setpoint corresponds to the suction throttling horsepower of the unit.

Maximum Motor Amps SetPt. - This setpoint (along with the Minimum Motor Amps
setpoint) determines the operating amperage range of the driver (motor). The MAX amps
setpoint corresponds to the design horsepower of the unit.

Inlet Valve Prop Band and Reset SetPt. - These setpoints control the responsiveness of
the inlet control valve/guide vanes. Refer to the Proportional Band and Reset section to
be discussed later in this chapter.

Unloading Valve Prop Band and Reset SetPt. - These setpoints control the
responsiveness of the unloading control valve. Refer to the Proportional Band and Reset
section to be discussed later in this chapter.

Valve Times (Inlet and Unloading) SetPt. - These setpoints determine the closing speed of
the inlet valve (in seconds) and the opening speed of the unloading valve in order to
obtain a smooth unloading of the compressor during intermittent and dual mode operation.

Valve Position To Auto Unload SetPt. - This setpoint determines the unloading valve
position, at which, a timer in the PLC software is initiated before unloading the compressor
on intermittent or auto dual mode control. Refer to the Intermittent or Auto Dual sections
later in this chapter.

Aux Oil Pump Shutoff Pressure SetPt. - This setpoint determines the oil pressure during
start-up of the compressor at which the auxiliary oil pump is permitted to shut off.

Oil Temp Start Permissive SetPt. - The permissive start setpoint determines the oil
temperature at which the compressor can be started. The PLC will not permit the
compressor to start until this oil temperature is attained.

Surge DP/DT SetPt. - These setpoints determine the sensitivity of the surge detection
system. Surge is detected when a certain pressure drop (DP) occurs within a certain time
period (DT).

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Adaptive Control Increment SetPt. - If compressor surge should occur, this setpoint
determines the amount of incremental adjustment, which the controls will move away from
surge. Every time the compressor surges, the controls make an incremental change until
compressor surge no longer exists or the maximum motor amperage is reached.

Surge Alarm Option SetPt. - This setpoint determines whether the PLC control system
annunciates an alarm during ADAPTIVE CONTROL. If 1 is selected, the unit will
automatically increment and reload during ADAPTIVE CONTROL and the PLC control
system will indicate an alarm (alarm light will flash and horn will sound). If O is selected,
the PLC control system will not indicate an alarm during surge as long as the adaptive
control increments the minimum motor amperage setpoint. Once the maximum motor
amperage setpoint is reached, the adaptive control will no longer reset the unloading valve
and the alarm will sound. Refer to the SURGE DETECTION section in Operation, Chapter
3 for further details.

Suction Throttle Prop Band and Reset SetPt. - These setpoints control the responsiveness
of the inlet control valve/guide vanes during the throttling action (suction throttling and dual
control modes). Refer to the Proportional Band and Reset section to be discussed later in
this chapter.

Modbus Address SetPt. - This setpoint is used to enter the correct modbus address when
communicating with the users DCS. The modbus option can be enabled or disabled from
the setpoint screen as well.

Sequencer Address Setpt. This setpoint is used to enter the correct sequencer address
when communicating with an external sequencer. The sequencer option can be enabled
or disabled from the setpoint screen as well.

10 Pt. Trip/Alarm Recording Time SetPt. In the event of an alarm or trip condition, the
panel will store 10 sets of data prior to the alarm or trip occurrence. This setpoint
determines the time interval between the 10 sets of stored data.

History Recording Time SetPt. - This setpoint determines the frequency (time intervals) in
which historical operating data is stored into the memory of the microcomputer.

Date and Time Set Setpt. This setpoint is used to enter the correct time and date into
memory.

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3 HISTORY

The PLC control system offers the capability to examine and print stored operating data.
To examine this information, press the HISTORY heading located on the PLC general
stats screen and the following screen will appear.


FIGURE 6-13
HISTORICAL DATA SCREEN

Select one of the history categories by pressing the respective heading. Each of the
history categories is explained below.

1-Trip Pressing this heading will display the last 10 trips the compressor
experienced. The date, time, description, value (if applicable), and units
of each trip will also be displayed.

2-Alarm Pressing this heading will display the last 10 alarms the compressor
experienced. The date, time, description, value (if applicable), and units
of each alarm will also be displayed.

3-Printer Menu Selecting the printer menu will display the screen shown below. This
menu is used to print various data from the PLC control system. The
options available in the print menu are described in further detail in
subsequent Print Data section.

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FIGURE 6-14
HISTORICAL DATA PRINT SELECTION SCREEN

4-Trend Selection The trend selection screen is shown below. The trend selection
screen allows the user to trend up to eight compressor parameters in
real time. The options available in the trend selection screen are
described in further detail in subsequent Trend Selection section.


FIGURE 6-15
TREND SELECTION SCREEN
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5-Start The Number of Starts field displays the total number of times the
compressor was started.

6-Surge The Number of Surges field displays the total number of times the
compressor has experienced a surge.

Printing Data
Referencing figure 6-14, the historical data print selection menu shows the various types
of data that can be printed. Each of these categories is explained below. Locally a serial
printer or Laptop can be used. A local printer or an optional remote serial printer can be
utilized for the printing of data. A RS-232/422 converter is needed for remote printing
beyond 50 feet. Pressing print history on the print selection screen will activate the local
printer. A print command from an optional remote HMI will activate the optional remote
operator interface. The local serial printer requires a Serial Printer cable. Refer to the
pin-out below.
DB9 (FEMALE) DB9(FEMALE)
1 open
2 3
3 2
4 6
5 5
6 4
7 8
8 7
9 9

SERIAL PRINTER CABLE

1-TR The last 10 trip conditions will print.
2-AL The last 10 alarm conditions will print.
3-STOP The PLC will stop sending data to the printer.
4-T/A 10 PT HIST The two TRIP & ALARM 10-point data sets will be printed.
5-HISTORY This choice will print history from a specified time period.

Selection 4 (T/A 10 PT History) will cause the PLC to print 10 sets of data prior to an alarm
or trip condition. Two such sets of data will be printed. These will be the two most recent
alarm and/or trip conditions, i.e., the last two alarms, the last alarm and the last trip, or the
last two trips. The data storage capacity is limited to two 10 point sets of data. Once an
alarm or trip condition occurs, the older of the two 10 point sets will be deleted to make
room for the most recent 10 point set. The time increment between the 10 sets of data is
variable and can be change on Setpoint Screen 5 (please reference the previous setpoint
section).

Selection 5 (History) will cause the PLC to print data, alarm conditions, and trip conditions
that have been recorded for the time frame entered. The "Start History At" is the
compressor run time in which you want data to begin printing. The current total run time of
the air compressor unit automatically appears on this screen. The "Stop History At" is the
compressor run time in which you want to stop printing.

Data is recorded once every time increment. The increment is variable and changed on
setpoint screen 5 (please see the previous setpoint section). The data storage capacity of
the PLC is limited to 2400 scans. Once 2400 scans is exceeded, the oldest data scan will
be deleted to make room for the most recent data scan. Use the following procedure to
print data.
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1. Select a Start History At time. To enter this time, press the hours field. A numeric
keypad will appear. Key-in the desired hour, then press the key to accept the new
setting. Repeat this process for both the minutes and seconds fields.


2. Select a Stop History At time. To enter this time, press the hours field. A numeric
keypad will appear. Key-in the desired hour, then press the key to accept the new
setting. Repeat this process for both the minutes and seconds fields.

3. Push the PRINT HISTORY button. The printer will begin to print.

NOTE
The PLC is capable of storing 2400 scans of data. Each
scan of data consumes one half of a page of paper. Thus, a
large volume of paper may be consumed.

Trend Selection

Performing a trend selection allows the user to trend up to eight operational parameters of
the compressor in real time. To create a trend graph perform the following steps.

1. Press the TREND SELECTION key on the historical data screen (reference figure 6-
13).

2. Select the first parameter (Pen 1) you would like to trend (the user will see the
current pen selection at the top of the screen). In this example LVT (Low Speed
Vibration Transmitter) is selected as Pen 1 (please reference figure 6-15). Press the
NEXT PEN key to continue to the next pen selection.

3. Select the second pen and push the NEXT PEN button, or select DISABLE PEN 2
to omit this pen from the trend. For this example, pen 2 will be disabled.

4. Select the third pen and push the NEXT PEN button, or select DISABLE PEN 3 to
omit this pen from the trend. For this example, pen 3 will be disabled.

5. Select the fourth pen and push the NEXT PEN button, or select DISABLE PEN 4 to
omit this pen from the trend. For this example, pen 4 will be configured to IOT (Inlet
Oil Temperature). Please reference figure 6-16 below.

NOTE:
The user has the option to trend up to 8 pens. For
this example, two pens will be selected, and the
remaining pens will be disabled.



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FIGURE 6-16
TREND SELECTION (PEN 4) SCREEN

6. Press the TREND GRAPH 1 key. The trend graph screen will appear (reference
figure 6-17). This screen shows the current parameters selected on the bottom of
the screen, and the current time.


FIGURE 6-17
TREND GRAPH 1 SCREEN
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7. The user also has the option to Trend Graph 2. This trend has 4 pre-selected
parameters to monitor (Inlet Valve, Unloading Valve, Motor Amps Transmitter, and
Discharge Pressure Transmitter). To view trend graph 2, press the TREND
SELECTION key on the historical data screen, then press TREND GRAPH 2.


FIGURE 6-18
TREND GRAPH 2 SCREEN





4 - DATA

Operating data, such as pressures, temperatures, and amperage, can be displayed on the
PLC control system. Although most of the crucial operating parameters are displayed on
the general status screen during operation, the following procedure can be used to
examine all of the operating data.

1. Press the STATUS button on the PLC touch screen. Once the general status screen
appears, press the DATA button, and the following screen will appear.










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FIGURE 6-19
DATA DISPLAY SELECTION SCREEN


2. The PLC control system utilizes a maximum of 32 analog inputs (some of which are
optional and may not be utilized by all users) and 2 analog outputs. Selecting
ANALOG DATA SCREEN 1 from the data display selection screen will display 13
analog inputs and the two analog outputs (please reference figure 6-20 below).

FIGURE 6-20
ANALOG DATA SCREEN 1

3. Selecting ANALOG DATA SCREEN 2 from the data display selection screen will
display the remaining analog inputs and their current value (please reference figure
6-21 below).
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FIGURE 6-21
ANALOG DATA SCREEN 2

Table 6-1 gives a description of the abbreviations that are displayed on the analog data
screens. Several of the data symbols are optional and may not apply to every compressor.


TABLE 6-1
DATA SYMBOLS

Temperature Transmitters

IAT Final Interstage Air Temperature Transmitter (
o
F)
IOT Inlet Oil Temperature Transmitter (
o
F)
IMT Driver Inboard Bearing Temperature Transmitter (
o
F)
OMT Driver Inboard Bearing Temperature Transmitter (
o
F)
SMT1 Motor Stator Temperature Transmitter (
o
F)
FIT First Interstage Air Temperature Transmitter (
o
F)
ACT Aftercooler Air Temperature Transmitter (
o
F)
ATT Inlet Air Temperature Transmitter (
o
F)
SMT2 Motor Stator Temperature Transmitter 2 (
o
F)
SMT3 Motor Stator Temperature Transmitter 3 (
o
F)
HOT High Speed Oil Temperature Transmitter (
o
F)
BOT Bullgear Oil Temperature Transmitter (
o
F)
LOT Low Speed Oil Temperature Transmitter (
o
F)
DTT Final Discharge Air Temperature Transmitter (
o
F)
ORT Oil Reservoir Temperature Transmitter (
o
F)
IATT Final Interstage Temperature Trip (
o
F)
IOTT Inlet Oil Temperature Trip (
o
F)
WTT Cooling Water Temperature Transmitter (
o
F)


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TABLE 6-1
(continued)


Pressure Transmitters

DPT Discharge Air Pressure Transmitter (psig)
SPT Plant Air System Pressure Transmitter (psig)
OPT Oil Pressure Transmitter (psig)
AFDP Air Filter Differential Pressure Transmitter (psig)
OFT Oil Filter Inlet Pressure Transmitter (psig)
FDT First Stage Discharge Pressure Transmitter (psig)
SDT Second Stage Discharge Pressure Transmitter (psig)
IPT Inlet Air Pressure Transmitter (psig)
WPT Cooling Water Pressure (psig)
OPTT Inlet Oil Pressure Transmitter Trip (psig)
MOPT Main Oil Pump Pressure Transmitter (psig)


Vibration Transmitters

LVT Low Speed Pinion Vibration Transmitter (mils p-p)
HVT High Speed Pinion Vibration Transmitter (mils p-p)
LVTX Low Speed Pinion Vibration Transmitter X Probe (mils p-p)
HVTX High Speed Pinion Vibration Transmitter X Probe (mils p-p)
LVTY Low Speed Pinion Vibration Transmitter Y Probe (mils p-p)
HVTY High Speed Pinion Vibration Transmitter Y Probe (mils p-p)
IDTX Driver Inboard Vibration Transmitter X Probe (mils p-p)
ODTX Driver Outboard Vibration Transmitter X Probe (mils p-p)
IDTY Driver Inboard Vibration Transmitter Y Probe (mils p-p)
ODTY Driver Outboard Vibration Transmitter Y Probe (mils p-p)
AXL Compressor Axial Single Transmitter (mils p-p)


Other Analog Transmitters

MAT Motor Amperage Transmitter (amps)
IVT Inlet Valve Position (% Open)
UVT Unloading Valve Position (% Open)
DST Turbine Driver Speed Transmitter (RPM)
UDT1 User Defined Transmitter 1
UDT1 User Defined Transmitter 2







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Trip and Alarm Settings

The following procedure can be used to adjust trip and alarm settings.

WARNING
Incorrect trip and alarm settings can lead to
catastrophic damage on the air compressor; therefore, it
is strongly recommended that a service engineer be
contacted before the user manipulates the trip and
alarm settings.

1. Press the STATUS button on the PLC touch screen. Once the general status screen
appears, press the DATA button to access the Data Display Selection screen
(reference figure 6-19).

2. Access either analog screen 1 or 2 by pressing the appropriate choice on the Data
Display Selection screen (reference figure 6-20 or 6-21).

3. Press on the data symbol associated with the analog input or output you would like
to change the alarm and trip values for. In this example, the Inlet Oil Pressure is
used (reference figure 6-22 below).


FIGURE 6-22
INLET OIL PRESSURE TRIP AND ALARM ADJUSTMENT SCREEN


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4. To change the alarm or trip values, press the appropriate field where the current
value is displayed (the alarm or trip must be enabled for a value to be displayed),
and a numeric keypad will appear. Key in the desired numeric value, then press the
key to accept the new value (the level 1 password will be required to change the
alarm and trip values).

WARNING
Changing any of the parameters on the Alarm and Trip
Adjustment screens can have an adverse affect on the
performance of the air compressor. It is strongly
recommended that a service engineer be contacted
before any of these parameters are changed.

Transmitter Test & Calibration Procedures

1. Shut down the compressor (chapter 3).

2. Apply a known pressure or temperature to the desired transmitter (within the range
of the transmitter). Refer to the nameplate on the transmitter.

3. Press the STATUS button on the PLC touch screen. Once the general status screen
appears, press the DATA button to access the Data Display Selection screen
(reference figure 6-19). Select either analog data screen 1 or analog data screen
2 depending on the transmitter in question.

4. Confirm that the current value of the transmitter matches the test signal.

5. If necessary, re-calibrate the transmitter with the procedure described in the
following steps.

6. For a temperature calibration, start with a known temperature reference (i.e., put
RTD into an ice bath). Access the RTDs data menu, and enter the known reference
temperature into the CAL REF 1 (MIN) field (reference figure 6-22). Give two
reference temperatures (perhaps 32F and 212F). From these two points, the
proper adjustments will be made.

5-OIL SYS

The PLC Oil System screen is a status screen for the oil system. This screen displays
values such as the inlet oil pressure, inlet oil temperature, oil reservoir temperature (if
applicable), the low and high-speed vibrations, and the oil filter differential pressure.

1. To access the Oil Sys screen, press the STATUS button on the PLC touch screen.
Once the general status screen appears, press the OIL SYS button to access the
Oil System screen (reference figure 6-23).
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FIGURE 6-23
OIL SYSTEM SCREEN

6-MODE

The PLC Mode screen is accessed to manipulate the compressor control modes (base,
suction throttle, intermittent, or auto-dual), the start/stop sequence (automatic or manual),
and the operation of the inlet valve or unloading valve (manual or automatic).

NOTE
It is recommended that the mode screens be reviewed
before each start-up to ensure the desired compressor
operation will be obtained.


1. To access the mode screens, press the STATUS button on the PLC touch screen.
Once the general status screen appears, press the MODE button to access the
Mode Screen screen (reference figure 6-24).

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FIGURE 6-24
MODE SELECTION SCREEN

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Manual Operation - Inlet Valve/Guide Vanes

Manual Operation of the inlet control valve/guide vanes allows the operator to manually
adjust the compressor inlet airflow, which, in turn, affects the driver load (motor current).
Manual control of the inlet control valve/guide vanes can be obtained by selecting the
INLET VALVE drop-down menu (located on the mode selection screen) and pushing
MANUAL (the valve is now in manual control). Up and down arrows will appear
(reference figure 6-25). The arrows can be pressed repeatedly to change the position of
the valve. The motor current will change accordingly. Decreasing the % open value will
reduce the driver load (motor current).


FIGURE 6-25
INLET VALVE IN MANUAL MODE


NOTE
Unattended manual operation is not recommended since
changes in the compressor inlet air temperature affect the
driver load and compressor surge.


NOTE
Manually closing the inlet control valve/ guide vanes too far
during compressor operation may result in compressor
surge.



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Automatic Operation - Inlet Valve/Guide Vanes

Automatic operation of the inlet control valve/guide vanes allows the control panel to
automatically adjust the driver load (motor current). The control panel will automatically
maintain the driver load at the setpoint. The motor current setpoint is described in the
setpoint section of this chapter. Automatic control can be obtained by selecting the
INLET VALVE drop-down menu (located on the mode selection screen) and pushing
AUTO (the valve is now under automatic control).

Manual Operation - Unloading Valve

Manual operation of the unloading control valve allows the operator to manually adjust the
compressor discharge pressure. Manual control of the unloading valve can be obtained
by selecting the UNLOADING VALVE drop-down menu (located on the mode
selection screen) and pushing MANUAL (the valve is now in manual control). Up and
down arrows will appear (reference figure 6-26). The arrows can be pressed repeatedly
to change the position of the valve. The compressor discharge pressure will change
accordingly. Increasing the % open value will reduce the compressor discharge pressure.


FIGURE 6-26
UNLOADING VALVE IN MANUAL MODE

NOTE
Unattended manual operation is not recommended since
changes in the plant air demand effect compressor surge.

NOTE
Manually closing the unloading control valve too far during
compressor operation may result in compressor surge.
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Automatic Operation - Unloading Valve

Automatic operation of the unloading control valve allows the control panel to
automatically adjust the compressor discharge pressure. The control panel will
automatically maintain the compressor discharge pressure at the setpoint. The
compressor discharge pressure setpoint is described in the setpoint section of this
chapter. Automatic control can be obtained by selecting the UNLOADING VALVE
drop-down menu (located on the mode selection screen) and pushing AUTO (the valve is
now under automatic control).

Start/Stop Mode - Manual/Manual

An operator is required to physically push the necessary keys and buttons in order to start
and stop the air compressor unit. These steps are described in the Operation section.
Any of the control modes (base mode, suction throttling, intermittent, or dual) can be used
with manual/manual. Press the START/STOP MODE drop-down menu (please
reference figure 6-27 below), and select MANUAL/MANUAL (the start/stop mode is now
configured to manual/manual).


FIGURE 6-27
START/STOP MODE SELECTION

Start/Stop Mode - Auto/Manual

Automatic start-up requires an operator to only initiate the panel. These steps are
described in the Operation section. The control panel then automatically starts the
compressor when the plant air pressure decreases to the low system air pressure
setpoint. An operator is still required to physically stop the air compressor. Any of the
control modes (base mode, suction throttling, intermittent, or dual) can be used with
AUTO/MANUAL control. Press the START/STOP MODE drop-down menu (please
reference figure 6-27), and select AUTO/MANUAL (the start/stop mode is now configured
to auto/manual).


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Automatic Start/Automatic Stop

Automatic start-up requires an operator to only initiate the panel. These steps are
described in the Operation section. The control panel then automatically starts the
compressor when the plant air pressure decreases to the low system air pressure
setpoint. When the plant air system does not require the unit's compressed air for a
period of time, the control panel unloads the compressor (unloading control valve fully
opens and the inlet valve/guide vanes fully close). If the compressor is not required to
reload within 30 minutes, the control panel will automatically shut down the air compressor
unit. Press the START/STOP MODE drop-down menu (please reference figure 6-27),
and select AUTO/AUTO (the start/stop mode is now configured to auto/auto).

NOTE
Only intermittent or auto-dual mode can be used with
AUTO-AUTO control.

Base Mode Control

Base mode control maintains the design discharge pressure of the compressor by
modulating the unloading control valve. As the plant air demand decreases, the unloading
control valve will modulate (open) and blow off excess air to atmosphere. The inlet control
valve/guide vanes modulate to maintain the design motor current (amperage).

The setpoints required for base mode operation are listed below:

1. Discharge Air Pressure
2. Maximum Motor Current

To operate the compressor in base mode, access the CONTROL MODE drop-down
menu (located on the mode selection screen) and select BASE (the compressor will now
operate in base mode).

Suction Throttle Mode Control

The suction throttle control mode is a method of reducing the driver power consumption by
throttling the inlet airflow when the plant air system demand is satisfied. This method of
control is similar to base mode with the exception that when the plant air pressure
(compressor discharge pressure) is satisfied, the inlet control valve/guide vanes throttle
the inlet airflow. The inlet valve/guide vanes throttle the airflow until a minimum amperage
setpoint is reached. If the plant demand continues to decrease, the unloading control
valve will modulate to maintain design discharge pressure. The setpoints required for
suction throttle mode operation are listed below.

1. Discharge Air Pressure
2. Maximum Motor Current
3. Minimum Motor Current

To operate the compressor in suction throttle mode, access the CONTROL MODE
drop-down menu (located on the mode selection screen (reference figure 6-28)) and
select SUCTION THROTTLE (the compressor will now operate in suction throttle mode).
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FIGURE 6-28
CONTROL MODE SELECTION SUCTION THROTTLE

NOTE
If the minimum amps setpoint value is too low while
operating in suction throttle mode, the compressor may
surge. It is recommended that a suction surge test is
performed to determine the correct minimum amps
setpoint before the unit is placed in either suction throttle
or auto-dual mode. The test is explained later on in this
chapter.

Intermittent Mode Control

Intermittent mode is basically an ON-OFF type of control. The compressor loads and
unloads based on the plant air system demand. When the system air pressure is below
the low system air pressure setpoint, the inlet control valve/guide vanes open to maintain
design motor amperage and the unloading control valve closes to deliver all of the
compressed air to the plant air system. As the plant air system demand decreases, the
compressor discharge pressure increases and the unloading valve maintains design
discharge pressure by venting excess air to atmosphere. As the plant air system demand
further decreases, the unloading valve opens further to maintain design discharge
pressure. Once the valve position has exceeded the auto unload setpoint (% Open), a
timer is initiated. If the % open setpoint is exceeded for 3 minutes, the compressor
unloads (unloading control valve fully opens and the inlet valve/guide vanes fully close).
The compressor remains unloaded until the plant air pressure decreases to the low
system pressure setpoint at which time the cycle will begin again. The setpoints required
for intermittent mode of operation are listed below:

1. Low System Air Pressure
2. Final Discharge Air Pressure
3. Maximum Motor Current
4. Valve Position to Auto Unload

To operate the compressor in intermittent mode, access the CONTROL MODE drop-
down menu (located on the mode selection screen (reference figure 6-28)) and select
INTERMITTENT (the compressor will now operate in intermittent mode).
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NOTE
Due to the variations in unloading valves and piping
systems, the low system pressure setpoint and valve
position to unload setpoint must be field set. Below are
general guidelines for obtaining these setpoints.

The valve position to auto unload setpoint can be obtained by operating the unit in base
mode control with the system block valve closed. View the general status screen
(reference figure 6-1) to determine the % open position of the unloading valve (U/V PO) as
design discharge pressure is maintained. Subtract 10 from this % open value to obtain
the valve position to unload setpoint.

The low system pressure setpoint can be obtained by operating the unit in base mode
control with the system block valve open. Open system valves until the unloading valve is
nearly fully closed. View the general status screen (reference figure 6-1) and record the
compressor discharge pressure (DPT) and system pressure (SPT). Subtract the two
pressure readings to determine the pressure drop. Add 5 to the pressure drop. Subtract
this resultant from the discharge pressure setpoint to obtain the maximum low system
pressure setpoint. (The compressor will never unload if the low system pressure setpoint
is too high.)

Auto Dual Mode Control

Auto dual mode of control is the same as intermittent mode with the exception that once
the compressor discharge pressure rises to the design discharge pressure, the inlet
control valve/guide vanes throttle the inlet airflow to reduce the driver horsepower. The
inlet control valve/guide vanes throttle airflow until the minimum amperage setpoint is
reached.

If the system pressure (compressor discharge pressure) continues to increase the
unloading valve opens to maintain design discharge pressure. If the unloading valve
opens beyond the % open setpoint for the setpoint amount of time, the compressor
unloads (unloading valve fully opens and inlet valve/guide vanes fully close). The
compressor will continue to run in this unloaded state until the plant air system pressure
falls below the low system pressure setpoint. The compressor will then reload and the
cycle will repeat. The setpoints required for auto dual mode operation are listed below:

1. Low System Air Pressure
2. Final Discharge Air Pressure
3. Maximum Motor Current
4. Minimum Motor Current
5. Valve Position to Auto Unload


To operate the compressor in auto-dual mode, access the CONTROL MODE drop-
down menu (located on the mode selection screen (reference figure 6-28)) and select
AUTO/DUAL (the compressor will now operate in auto-dual mode).



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NOTE
Due to the variations in unloading valves and piping
systems, the low system pressure setpoint and valve
position to auto unload setpoint must be field set. Below are
general guidelines for obtaining these setpoints.

The valve position to auto unload setpoint can be obtained by operating the unit in suction
throttle control with the system block valve closed. View the data screens to determine the
% open position of the unloading valve (U/V PO) as design discharge pressure is
maintained. Subtract 10 from this % open value to obtain the valve position to auto unload
setpoint.

The low system pressure setpoint can be obtained by operating the unit in suction throttle
control with the system block valve open. Open system valves until the unloading valve is
nearly fully closed. View the data screens and record the compressor discharge pressure
(DPT) and system pressure (SPT). Subtract the two pressure readings to determine the
pressure drop. Add 5 to the pressure drop. Subtract this resultant from the discharge
pressure setpoint to obtain the maximum low system pressure setpoint. (The compressor
will never unload if the low system pressure setpoint is too high.)


7 TEST

The test screens display the status of the digital input and output channels. They also
allow testing of the auxiliary oil pump, alarm light, trip light, and optional horn.

1. To view the various test screens, press the STATUS button on the PLC touch
screen. Once the general status screen appears, press the TEST button to access
the first (digital input test screen) of three test screens (please reference figure 6-29).


FIGURE 6-29
DIGITAL INPUT TEST SCREEN
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The status of the digital inputs on the display screen should be compared to the status of
the digital input LEDs on the CPU module. The CPU module is capable of handling 24
digital inputs. Only the first 8 are typically used. They are the upper first half of the CPU
module. The lower half is for optional inputs. If the channel is closed, the LED should be
illuminated. If the channel is open or unused (NA), the LED should be extinguished.

DIGITAL INPUTS UPPER HALF/CPU MODULE DEVICE
0 0 Main Drive Motor Status
1 1 Seal Air Pressure Switch
2 2 Emergency Stop
3 3 Low Oil Level Switch
4 4 Remote Start
5 5 Remote Stop
6 6 Remote Unload
7 7 Customer Permissive Input

DIGITAL INPUTS LOWER HALF/CPU MODULE DEVICE
0 0 Turbine Trip Switch
1 1 Panel Purge Switch
2 2 Cooling Water Flow Switch
3 3 Spare
4 4 Spare
5 5 Spare
6 6 Spare
7 7 Spare

2. To access the digital output test screen (figure 6-30) press the NEXT key located on
the digital input test screen (reference figure 6-29).

FIGURE 6-30
DIGITAL OUTPUT TEST SCREEN
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The digital output test screen will display the digital outputs and whether the channel is
energized, or de-energized, or unused (NA). The following table describes the various
output channels.

The status of the digital outputs on the display screen should be compared to the status of
the digital outputs on the CPU module. If the channel is energized, the LED should be
illuminated. If the channel is de-energized or unused (NA), the LED should be
extinguished.


DIGITAL OUTPUTS UPPER HALF/CPU MODULE DEVICE
0 0 Motor/Turbine/Start/Trip/Stop
1 1 Aux Oil Pump
2 2 Cooling Water Solenoid
3 3 Horn
4 4 Common Alarm Light
5 5 Common Alarm Relay
6 6 Common Trip Light
7 7 Common Trip Relay

DIGITAL OUTPUTS LOWER HALF/CPU MODULE DEVICE
0 0 Turbine Solenoid Trip
1 1 Remote Common Trip
2 2 Permissive Output
3 3 Spare
4 4 Auto Turbine Solenoid Trip
5 5 Spare
6 6 Momentary Stop/Switchgear
7 7 Momentary Start/Switchgear


Manual Operation of the Auxiliary Oil Pump

The auxiliary oil pump can be operated manually (Test) or automatically (Normal). Manual
operation of the auxiliary oil pump can be obtained by following the procedure below.

1. Press the STATUS button on the PLC touch screen. Once the general status screen
appears, press the TEST button to access the first (digital input test screen) of three
test screens (please reference figure 6-29).

2. Press the NEXT button (reference figure 6-29) twice to access the Aux Oil
Pump/Lamp Horn Test Screen (reference figure 6-30).

3. Press the Aux Oil Pump drop-down menu and select TEST (the auxiliary oil pump
is now in test mode and will continuously operate).

NOTE
Manual operation of the auxiliary oil pump is required to test
the pump (check rotation) and check the operation of the
lube system before initial start-up. Otherwise, the auxiliary
oil pump should operate in the normal mode.
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4. Press the Aux Oil Pump drop-down menu and select NORMAL to place the
auxiliary oil pump back into its normal mode.

If the main oil pump should fail, the unit can be operated on the auxiliary oil pump by
placing it in the Test mode (Manual operation). It will also be necessary to lower the
auxiliary oil pump shutoff pressure setpoint below the normal operating oil pressure.

CAUTION
It is strongly recommended that the compressor not be
operated with a failed main oil pump. If the auxiliary oil
pump should stop under these conditions, such as, an
electrical power failure, etc., oil starvation will occur
resulting in bearing damage. Severe mechanical
damage to the compressor can occur.

Lamp and Horn Test
The alarm and trip lights and the horn can be tested by following the procedure below.

1. Press the STATUS button on the PLC touch screen. Once the general status screen
appears, press the TEST button to access the first (digital input test screen) of three
test screens (please reference figure 6-29).

2. Press the NEXT button (reference figure 6-29) twice to access the Aux Oil
Pump/Lamp Horn Test Screen (reference figure 6-31).

3. Press the LIGHTS drop-down menu and select ON to test the alarm and trip lights.
The lights will illuminate for three seconds.

4. To test the horn, press the HORN drop-down menu and select ON. The horn will
sound for three seconds.
FIGURE 6-31
AUX OIL PUMP/ LAMP / HORN TEST SCREEN
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8 CONFIG

There are several options within the configuration screens. Three of the configuration
menus can be accessed only by FS-Elliott authorized personnel. A higher-level (Level 2 -
Configuration) access code is required to gain entry into these Configuration screens.
However, the remaining configuration screens are accessible, and these screens are
explained below.

1. To access the configuration service screen menu, press the STATUS button on the
PLC touch screen. Once the general status screen appears, press the CONFIG
button to access the configuration service screen (reference figure 6-32).


FIGURE 6-32
CONFIGURATION SERVICE SCREEN


ADJ. ANALOG INPUT ENG. UNITS

1. Press the adj. analog input eng. units button located on the configuration service
screen (reference figure 6-32) to access the adjustable analog unit selection screen
(reference figure 6-33).

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FIGURE 6-33
ADJUSTABLE ANALOG INPUT ENG. UNIT SELECTION SCREEN

2. To change an engineering unit selection, press the UNIT SELECTION drop-down
menu and select the desired unit.

TIMER SETTINGS

1. Press the TIMER SETTINGS button located on the configuration service screen
(reference figure 6-32) to access the timer screen 1 (reference figure 6-34).


FIGURE 6-34
TIMER SCREEN 1

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2. To change a timer value, press the appropriate field where the current value is
displayed, and a numeric keypad will appear. Key in the desired time (in seconds),
then press the key to accept the new value.

NOTE
Among other things, the timer settings dictate the
sequence of events during start-up or shutdown; therefore,
it is strongly recommended that a service engineer be
contacted before any timer setting is changed.

3. Press the TO TIMER SCREEN TWO button located on Timer screen 1 (please
reference figure 6-34) to access timer screen two (please reference figure 6-35).


FIGURE 6-35
TIMER SCREEN 2

4. To change a timer value on timer screen 2, press the appropriate field where the
current value is displayed, and a numeric keypad will appear. Key in the desired
time (in seconds), then press the key to accept the new value.

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5. Press the TO TIMER SCREEN THREE button located on Timer screen 2
(please reference figure 6-35) to access timer screen three (please reference
figure 6-36).

FIGURE 6-36
TIMER SCREEN 3

6. To change a timer value on timer screen 3, press the appropriate field where the
current value is displayed, and a numeric keypad will appear. Key in the desired time
(in seconds), then press the key to accept the new value.

7. Press the TO TIMER SCREEN FOUR button located on Timer screen 3 (please
reference figure 6-36) to access timer screen four (please reference figure 6-37).


FIGURE 6-37
TIMER SCREEN 4
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6. To change a timer value on timer screen 4, press the appropriate field where the
current value is displayed, and a numeric keypad will appear. Key in the desired time
(in seconds), then press the key to accept the new value.

9 UTILITY

The utility screen displays information such as the customer unit number, compressor
serial number, compressor run time, and compressor power-on time. The screen also
provides the ability to toggle between English and Spanish text as well as the contrast
adjustment tools.

1. To access the utility screen, press the STATUS button on the PLC touch screen.
Once the general status screen appears, press the UTILITY button to gain access to
the utility screen (reference figure 6-38).


FIGURE 6-38
UTILITY SCREEN

2. To adjust the contrast calibration, press CONTRAST (-) to make the screen darker,
and press CONTRAST (+) to make the screen brighter.

3. To toggle the English/Spanish selection, press the ENGLISH/SPANISH SELECTION
button.

4. To enable or disable the print screen function, press the ENABLE/DISABLE PRINT
SCREEN button.

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SUCTION THROTTLE ADJUSTMENT PROCEDURE

Once system air pressure has been satisfied, the inlet valve automatically throttles. The
PLC control system senses the compressor discharge air pressure. When the discharge
air pressure reaches the discharge pressure setpoint, the PLC throttles the inlet valve to a
minimum motor amperage (less flow). Since less flow is entering the compressor, a power
savings is realized.

A suction throttling setpoint (MIN AMPS) was entered into the PLC at the factory. This
setpoint can be changed by referring to the setpoint section earlier in this chapter. The
following procedure can be used to determine the MIN AMPS setpoint/MIN DENSITY
setpoint.

1. Start the compressor in BASE control mode. Refer to Operation, Chapter 3 if
necessary.

2. Place the unloading valve in AUTO control. Slowly close the block valve to the plant
air system. The unloading valve should be maintaining design discharge pressure.

3. Place the inlet valve in MANUAL control.

4. Slowly reduce the % OPEN of the inlet valve. Record the Motor Amps just prior to
compressor surge.

5. Use the corresponding equation below to determine the MIN AMPS setpoint. This
setpoint maintains a 25% safety margin from surge.

MIN AMPS =(MAX AMPS - Surge AMPS) .25 +Surge Amps



CAUTION
Excessive throttling of the inlet valve will result in
compressor surge. Operating the unit in a continual
surge condition can cause extensive damage to the
compressor.


6. Open the block valve to the plant air system. Press the ACK and RESET buttons on
the general status screen to clear the surge alarm.

7. Adjust the MIN AMPS setpoint per the equation above. Place the compressor in
Suction Throttle control mode.

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PROPORTIONAL BAND AND RESET

The proportional band and reset settings determine the responsiveness of the control
valves (inlet valve and unloading valve). The standard settings are programmed into the
PLC at the factory. These settings have proven to be sufficient in most applications.
However, some applications may require minor adjustments to the proportional band
and/or reset settings in the field.

NOTE
The proportional band and reset setpoints should not be
changed arbitrarily. Changing the setpoints can result in
compressor surge.

Proportional Band (Input to Output %)

1. The lower the proportional band setting - the faster the valve reacts to system
changes.
NOTE
If the setting is too low, the valve will become unstable
(continuously oscillate).

2. The higher the proportional band setting - the slower the valve reacts to system
changes.
NOTE
If the setting is too high, the valve will become sluggish
(move too slow).

Reset (Repeats per Minute)

1. The lower the reset setting - the slower the valve returns to the desired operating
point.
NOTE
If the setting is too low, the valve will become sluggish
(move too slow).



2. The higher the reset setting - the faster the valve returns to the desired operating
point.
NOTE
If the setting is too high, the valve will become unstable
(continuously oscillate).


MOTOR PROTECTION

Excessive motor starts in a short period of time will reduce the motor life and can cause
motor damage. NEMA standards state that a motor may have two cold starts or one hot
start per hour. A cold start is defined as a start with the motor at ambient temperature and
a hot start as one with the motor at normal operating temperature.
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The PLC monitors the number of starts. If a start beyond the NEMA standard is
attempted, the motor will not start and the following screen will appear.



FIGURE 6-39
HOT MOTOR SCREEN

Certain situations may dictate a start beyond the NEMA standard, such as, certain
troubleshooting techniques or users may be less concerned with the longevity of the motor
than with fulfilling the plant's air demand. In these situations, an operator can override this
protection as explained below.

CAUTION
Excessive motor starts will reduce motor life.

1. Push the START key on the PLC general status window. If a hot motor condition
exists, the screen will prompt the user and provide the option to bypass the condition
(reference figure 6-39).

2. Press the bypass button on the PLC screen, and use the keypad to enter the level
one password when prompted. Press the key to accept the code (the hot motor
condition will now be bypassed).

3. Push the START key again to start the compressor.

The driver motor may also be equipped with optional temperature detectors (RTD) in the
motor stator and/or the motor bearings. The PLC will indicate an alarm or trip if the
respective setpoints are exceeded.
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COMMUNICATION

There are numerous methods available for communicating with the digital microcomputer.
These are described below. Some of these communication methods are optional.

Local Operator Interface and Local Printer

A local operator interface (HMI display) and a port for local printing are standard on all
control panels. The operator interface was explained in detail earlier in this chapter.

A Printer/Config. port is located on the underneath side of the HMI display. This port can
be used to capture historical data via laptop or sent to a printer. A DB9 connector is
utilized if the user plans to drive a serial printer.

Screen captures can be obtained providing the customer selects the ENABLE/DISABLE
PRINT SCREEN function from the UTILITY Screen. A USB connector is provided on the
underneath side of the HMI display if the user plans to connect a USB printer.

Remote Operator Interface and Remote Printer

A remote operator interface (HMI display) and remote printer are optional. In order to use
the remote printer, a remote operator interface is also required.

The preferred printer to use is a serial printer with DSR/DTR type hardware handshaking.
Other printer types can be utilized, assuming they use some form of handshaking.

Host Computer Interface

The host computer interface option allows any host computer to communicate with the
control panel via modbus. The control panel will respond to RTU command strings from
any host computer (or stand alone terminal) to send historical data, change setpoints, and
echo setpoint values.

Sequencer Interface

The sequencer interface option is used when a sequence control panel has been installed.
A sequencer control panel controls the starting and stopping of a number of air
compressor units. As the plant air demand varies, the sequencer panel automatically
starts and stops air compressor units to match the plant air demand.

REMOTE START/STOP
Remote Start

The Remote Start Option allows the compressor to be started from a remote location. The
Remote Start digital input utilizes the same starting logic and algorithms as the Start key
located on the Touch panel display.

The Remote Start digital input is Edge triggered. As such, in order to remotely start the
compressor, the digital input must see its input transition change from Open (0 Vdc) to
Closed (24 Vdc).
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-Contact Closure- A simple contact closure will also provide the appropriate signal
to remotely start the compressor. The contact can remain
closed without consequence, however the contact will have to
be reset (reopened) before the next remote start of the
compressor.

Remote Stop

The Remote Stop Option supplies the user with the ability to shutdown the compressor
from a remote location. The Remote Stop option can be configured in two different ways.
It can be configured as a Hard Stop (Emergency Stop) or as a Soft Stop. The Hard
Stop stops the compressor in the same manner as the Emergency Stop push button on
the front of the control panel. The main driver is immediately stopped and at the same
time, the unloading valve is fully opened. Stopping the unit in this manner may cause the
compressor to experience a mild surge. Although this surge will not damage the
compressor, it is preferred that this condition be avoided when possible.

The Soft Stop stops the compressor in the same way as pushing the Stop Key on the local
Touch Screen. The compressor is first unloaded (unloading valve fully opened, inlet valve
fully closed) prior to shutdown of the main driver. Stopping the unit in this manner prevents
the above mentioned surge condition.


Non-Emergency Stop Situations (Soft Stop)
When a remote stop switch is to be used in non-emergency situations, it is recommended
that the soft stop option be configured for shutdown of the compressor. This will cause the
compressor to unload prior to shutdown of the main driver.


Emergency Stop Situations (Hard Stop)
When a remote stop switch is to be used in emergency situations, the remote stop digital
input should be configured for the hard stop option. This will cause both the main driver to
stop and the unloading valve to open immediately.

The Remote Stop digital input is Edge triggered as with the Remote Start. Unlike the
Remote Start, in order to remotely stop the compressor, the digital input must see its input
transition change from Closed (24Vdc) to Open (0 Vdc).



-Contact Opening -A simple contact opening will also provide the appropriate
signal to remotely stop the compressor. The contact can
remain open without consequence, however the contact will
have to be reset (reclosed) before the unit will be allowed to
start.



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SEAL AIR PRESSURE SWITCH (SAPS)

The Seal Air Pressure Switch (SAPS) senses the buffer pressure in the compressor seals.
The Seal Air Pressure Switch (SAPS) is used in conjunction with intermittent mode or dual
mode control. The SAPS is ignored during base mode and suction throttle mode control.

Low seal air pressure is an alarm condition (optional horn, common alarm light, and
display on the operator interface). A low seal air pressure condition also prevents the inlet
valve/guide vanes from closing (unload compressor) and prevents the auxiliary oil pump
from continuously running during start-up. The switch is set so that the contacts close at 4
psig (0.27 bar) and open at 2 psig (0.13 bar).

A blow-off regulator is installed on the seal air harness to vent air should the air pressure
exceed 6.5 psig (0.45 bar).

FILTER MONITORING PACKAGE (OPTIONAL)

Oil Filter P Transmitter (OFDP)
The Oil Filter Differential Pressure Transmitter is installed on the baseplate and wired back
to the PLC. The transmitter senses oil pressure before the oil filter in the high-pressure
port and after the oil filter in the low-pressure port.

Air Filter P Transmitter (AFDP)
The Air Filter Differential Pressure Transmitter is field installed near the inlet filter. The
low-pressure port should be connected to a pressure port downstream of the air filter. The
high-pressure port should be left open to atmospheric pressure. The transmitter should
activate alarm setting in the control panel when the pressure drop across the filter exceeds
10" W.C. above the clean filter pressure drop.


VIBRATION PROBES

Optional vibration probes are installed in the gear case to monitor pinion vibration.

Replacement

1. Remove the cover from the vibration conduit junction box.

2. Unthread the probe wire lead from the vibration cable.

3. Unthread the vibration conduit junction box from the gear case connector.

4. Loosen the thread seal nut and flat washer, which holds the vibration probe to the
connector.

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5. Unthread the vibration probe from the connector.

6. Apply a small amount of Silastic on the threads of the vibration probe, then install the
replacement probe into the connector until the probe contacts the rotor shaft.

NOTE
Do not apply excessive force to the probe against the shaft
since the probe tip can become damaged.

7. Connect the probe wire lead to the vibration cable. Adjust probe for proper gap as
explained below.


Adjustment

1. Record the probe gap voltage. Install the leads from a voltmeter across terminals
COM and TEST of the Metrix vibration transmitter and/or COM and PROX on the
Bently Nevada vibration transmitter, depending on the type of transmitter being used
in the panel.

2. Slowly turn the vibration probe away from the shaft until 7-9 VDC is obtained if the
Bently Nevada vibration transmitter is being used or 4-6 VDC if the Metrix vibration
transmitter is being used.

CAUTION
Be sure that the probe tip is initially placed against the
rotor shaft. If the probe tip is positioned near the gear
case, a proper gap voltage of 7-9 VDC or 4-6 VDC,
depending on the type of transmitter being used, can be
recorded but the rotor vibration will not be sensed by
the probe.

3. Tighten the thread seal nut and recheck the gap voltage.

4. Disconnect the probe wire lead from the vibration cable and thread the vibration
conduit junction box onto the gear case connector.

5. Reconnect the probe wire lead to the vibration cable.

6. Install the cover onto the conduit junction box.











Chapter 6
Control System
PLC.ch06 10in.08/04/2006
6-50


Access Code
In order to change setpoints, the four-digit access code is located in the data section. The
procedure below can be used to locate the access code.

1. Press the (Data) key from any screen.

2. Select any analog input from Analog Data Screen1 or Analog Data Screen 2
(screen 2 is optional). The data screen shown below appears on the operator
interface.

3. Press HELP located in the upper right hand corner of the screen. The Info Text
Box appears defining the password levels. The operator access code is the
four-digit number listed as Level 1 Password (default value 1234).



FIGURE 6-40
DATA SCREEN / ACCESS CODE

Certain situations may exist, in which it is desirable to change the Access Code. In such
cases, it is necessary to contact FS-Elliott Company to obtain the procedure.




CLOSED
YES
YES
YES
NO
CONTINUE TO NEXT
PAGE
NO
UNIT FAILS TO
START
CHECK
CIRCUIT BREAKER
OPEN
SETPOINTS
CORRECT?
CHECK FOR
IMPROPER
SETPOINTS
CORRECT SETPOINTS AND
RESTART UNIT
NO
CHECK RELAY (CR1) RELAY FUNCTIONAL?
LOCK OUT MAIN MOTOR/TURBINE
TO PREVENT FROM STARTING
REPLACE RELAY AND RESTART
UNIT
NO
CHECK E-STOP
SWITCH
E-STOP FUNCTIONAL?
REPLACE E-STOP AND RESTART
UNIT
NO
CHECK OPERATOR
INTERFACE SCREEN
FOR TRIP
CONDITION
TRIP
CONDITION PUSH RESET KEY ON OPERATOR
INTERFACE RESTART UNIT
YES
CHECK OPERATOR INTERFACE
FOR CAUSE Verify that a possible
non-configured analog input from
the Data Selection is set to the
ENABLE position.
CHECK OPERATOR
CPU FAILURE FOR
SYSTEM FAULT
FAULT? YES
NOTE: Replacement parts should be purchased from FS-Elliott Company. Many of the
vendor parts have been modified and/or calibrated by FS-Elliott Company for compatibility
with the design. Parts that are purchased directly from vendors may not function properly
and could damage other components. Refer to FS-Elliott.com for your local representative.
DETERMINE CAUSE AND RESET
BREAKER
TROUBLE #1: Air Compressor Fails to Start
REMOTE STOP CONTACT
CLOSED?
CLOSE THE REMOTE STOP
CONTACT AND RESTART
NO
YES
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-1
PREVIOUS PAGE
NO
NO
NO
NO
CHECK DRIVER
MOTOR
OVERLOAD
TRIPPED?
REFER TO ITEM 5
YES
INSPECT WIRING
BETWEEN
STARTER AND
MOTOR
DAMAGE?
REPAIR WIRING AND
RESTART
YES
INSPECT
CONTROL PANEL
FOR FAILED
COMPONENT
FAILURE
LOCATED?
REPLACE COMPONENT
AND RESTART
YES
INSPECT
STARTER FOR
MALFUNCTION
MALFUNCTION?
RESET, REPAIR, OR
REPLACE COMPONENT
AND RESTART
YES
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
NO
INSPECT DRIVER
FOR
MALFUNCTION
MALFUNCTION?
FOLLOW
MANUFACTURERS
INSTRUCTIONS FOR
REPAIR
YES
TROUBLE #1: Air Compressor Fails to Start, continued
Troubleshooting Guide R300 / R200 / R150
7-2 visio-chap 7 r150-r200-r300 3-5-08
YES
NO
NO
YES
POWER SUPPLIED
TO PANEL
POWER?
APPLY POWER TO PANEL
NO
CIRCUIT BREAKER
TRIPPED IN DMC
TRIPPED?
RESET BREAKER
YES
LOOSE CONNECTION
BETWEEN OPERATOR
INTERFACE AND POWER
SUPPLY
POOR
CONNECTION?
RECONNECT OR REPLACE
CABLE
YES
CHECK POWER
SUPPLY
GREEN LIGHT
ON?
CHECK POWER TO DC POWER
SUPPLY. CHECK DC OUTPUT
VOLTAGE. REPLACE DC POWER
SUPPLY IF NECESSARY
NO
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
NO
INSPECT
OPERATOR
INTERFACE
DEFECTIVE?
REPLACE OPERATOR
INTERFACE IF NECESSARY
YES
TROUBLE #2: Operator Interface Display is Blank
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-3
REPLACE FILTER
ELEMENTS
INSPECT INLET
AIR FILTER
ELEMENTS
DIRTY?
INSPECT FOR
INLET AIR
OBSTRUCTION
OBSTRUCTION
REMOVE OBSTRUCTION
CHECK
INTERSTAGE
TEMPERATURES
HIGH?
OPEN WATER BALANCE VALVES IF
INSTALLED. CHECK WATER
TEMPERATURES AND FLOW.
CLEAN INTERCOOLER TUBE
BUNDLES IF NECESSARY
REPLACE TRANSMITTER
IMPROPER
MOTOR
CURRENT
SETPOINT
SETPOINT LOW?
RAISE SETPOINT TO
CORRECT DESIGN VALUE
HIGH INLET
TEMPERATURE
YES/NO
ADJUST CONTROL
SYSTEM TO ADJUST FOR
ABNORMALLY HIGH
AMBIENT TEMPERATURES
INSPECT
DISCHARGE
PRESSURE
TRANSMITTER
DEFECTIVE?
CONTINUE TO NEXT PAGE
VALVE
CONTROL
MANUAL
CHANGE VALVE CONTROL
TO AUTO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
TROUBLE #3: Compressor Surge
Troubleshooting Guide R300 / R200 / R150
7-4 visio-chap 7 r150-r200-r300 3-5-08
INSPECT
IMPELLERS,
DIFFUSERS AND
BACKPLATES
DIRTY?
CLEAN DIRTY
COMPONENTS
DAMAGED OR
WORN?
REPLACE WORN
COMPONENTS
COMPRESSOR
RUNNING AT
DESIGN
SPEED?
YES/NO
CONSULT DRIVER
MANUFACTURER
CONTACT FS-ELLIOTT
FOR AUTHORIZED
DISTRIBUTOR.
PREVIOUS PAGE
YES
NO
YES
NO
YES
NO
INSPECT
ANALOG INPUT
MODULE
DEFECTIVE?
VERIFY THAT THE SYSTEM
FAULT INDICATOR IS NOT
ILLUMINATED. REPLACE
ANALOG INPUT MODULE IF
NECESSARY
TEST
UNLOADING
VALVE
FUNCTION
DOES VALVE
OPEN?
REFER TO ITEM 14
TEST INLET
VALVE
FUNCTION
DOES VALVE
OPEN?
REFER TO ITEM 13
NO
YES
NO
NO
YES
NO
Yes
TROUBLE #3: Compressor Surge, continued
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-5
ADJUST DISCHARGE
PRESSURE SETPOINT TO
DESIGN VALUE
DISCHARGE
PRESSURE
SETPOINT TOO
LOW?
YES
UNLOADING
CONTROL VALVE
SETTING
AUTO/
MANUAL
CHANGE VALVE CONTROL TO
AUTO
DEFECTIVE
ANALOG INPUT
MODULE
DOES VALVE OPEN?
VERIFY THAT THE SYSTEM FAULT
INDICATOR IS NOT ILLUMINATED.
REPLACE ANALOG INPUT MODULE IF
NECESSARY
REFER TO ITEM 14
INSPECT
DISCHARGE
PRESSURE
TRANSMITTER
DEFECTIVE?
REPLACE TRANSMITTER
COMPRESSOR
UNLOADED?
MODE
WAIT UNTIL SYSTEM DEMAND
RELOADS COMPRESSOR
TEST UNLOADING
VALVE FUNCTION
DOES VALVE OPEN?
EXCESSIVE
SYSTEM DEMAND?
YES
START ANOTHER
COMPRESSOR
INTERMITTENT
AUTO DUAL
OTHER MODES
YES
NO
YES
NO
MANUAL
AUTO
YES
NO
YES
NO
NO
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
NO
TROUBLE #4: Compressor Fails to Develop Design Pressure
Troubleshooting Guide R300 / R200 / R150
7-6 visio-chap 7 r150-r200-r300 3-5-08
INVESTIGATE PANEL AND
CONSULT FACTORY FOR
PROPER ADJUSTMENT
INLET CONTROL
VALVE SETTING
AUTO
INLET CONTROL
VALVE SETTING
MANUAL
CHANGE VALVE CONTROL TO
AUTO
IMPROPER MOTOR
STARTER
SETPOINTS
YES/NO
INVESTIGATE PANEL AND
CONSULT FACTORY FOR
PROPER ADJUSTMENT
REFER TO ITEM 13
INSPECT
DISCHARGE
PRESSURE
TRANSMITTER
DEFECTIVE?
REPLACE TRANSMITTER
COMPRESSOR
OVERLOADED OR
MOTOR TRIP?
MOTOR CURRENT
SETPOINT HIGH? (Density
if Turbine)
ADJUST SETPOINT TO DESIGN
VALUE
TEST INLET VALVE
FUNCTION
DOES VALVE OPEN?
LOW AMBIENT
(INLET)
TEMPERATURE
YES/NO
INLET TEMPERATURES BELOW
DESIGN VALUES MAY OVERLOAD
MOTOR. THROTTLE INLET VALVE/
GUIDE VANE UNTIL DESIGN MOTOR
VOLTAGE IS ACHIEVED
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
CONTACT FS-ELLIOTT FOR
AUTHORIZED
DISTRIBUTOR.
NO
TROUBLE #5: Main Motor overloads trip and/or increased power usage
(steam consumption, if turbine driven).
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-7
SURGE NOT
DETECTED OR
FALSE SURGE
INDICATED
STABLE PLANT
DEMAND
A SUDDEN PLANT
PRESSURE DROP CAN
TRIGGER A FALSE SURGE
REVIEW PLC
SETPOINTS
CORRECT?
CHANGE SETPOINTS OR
CONTACT AUTHORIZED
SERVICE REP FOR
ASSISTANCE
REVIEW SURGE
TIME (DT) AND
SURGE
DIFFERENTIAL
(DP) SETPOINTS
CORRECT
CHANGE SETPOINTS OR
CONTACT AUTHORIZED
SERVICE REP FOR
ASSISTANCE
TEST DISCHARGE
PRESSURE
TRANSMITTER
DEFECTIVE?
REPLACE TRANSMITTER
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
NO
YES
NO
YES
NO
YES
YES
NO
TROUBLE #6: Controls do not detect surge or indicator light
indicates false surge.
Troubleshooting Guide R300/ R200 / R150
7-8 visio-chap 7 r150-r200-r300 3-5-08
LUBRICATE COUPLING
INSPECT COUPLING
NEEDS
LUBRICATION
COUPLING
MISALIGNMENT
COUPLING
ALIGNED?
ALIGN COUPLING
LOOSE OR BROKEN
HOLD DOWN BOLTS
BOLTS
LOOSE?
TIGHTEN/REPLACE
BOLTS AS NECESSARY
WORN COUPLING
COUPLING
WORN?
REPLACE COUPLING
INSPECT VIBRATION
MONITORING
SYSTEM
IMPROPER
ADJUSTMENT
ADJUST / REPLACE
MONITORING SYSTEM
AS REQUIRED
CONTINUE TO NEXT PAGE
WATER IN AIR
STREAM
WATER
PRESENT?
CLEAN DRAIN VALVE
ORIFICES IF PLUGGED.
INSPECT INTERCOOLER
TUBE BUNDLES AND
REPAIR IF NEEDED
YES
NO
YES
NO
YES
NO
NO
YES
YES
NO
YES
NO
TROUBLE #7: Excessive Vibration
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-9
CONSULT VIBRATION
SPECIALIST
INSPECT FACILITY FOR EXTERNAL VIBRATIONS
TRANSMITTING TO COMPRESSOR
INSPECT PINIONS/
BULL GEAR FOR
TOOTH DAMAGE
DAMAGE?
REPLACE GEARING AS
REQUIRED
INSPECT
INSTALLATION FOR
PIPING STRAIN
STRAIN PRESENT?
ADD PIPING SUPPORTS,
SPRING HANGERS AND / OR
EXPANSION JOINTS AS
NEEDED TO RELIEVE
INDUCED VIBRATIONS
NO
YES
NO
INSPECT
IMPELLERS/CASING
FOR RUBBING
RUB PRESENT?
DETERMINE ROOT CAUSE OF
PROBLEM AND REPLACE
WITH BALANCED ROTOR
ASSEMBLY
ROTOR UNBALANCE TEST BALANCE REBALANCE ROTOR
ASSEMBLY OR SEND TO
FACTORY FOR BALANCE
INSPECT SEALS FOR
DAMAGE/WEAR
DAMAGED/WORN?
REPAIR OR REBUILD SEALS
CLEAN IMPELLERS
INSPECT IMPELLERS
FOR DIRT BUILD UP
DIRTY?
PREVIOUS PAGE
NO
NO
NO
YES
YES
YES
YES
YES
NO
TROUBLE #7: Excessive Vibration, continued
Troubleshooting Guide R300/ R200 / R150
7-10 visio-chap 7 r150-r200-r300 3-5-08
AUX. OIL PUMP MOTOR
FAILS TO START
TRIP
CONDITION
RESET OVERLOADS
YES
NO
TEST RELAY AND REPLACE,
IF DEFECTIVE
CHECK CR2 RELAY DEFECTIVE?
NO
YES
REPLACE CPU
CHECK OUTPUT CHANNEL
ON CPU MODULE
DEFECTIVE? YES
NO
REPLACE TRANSMITTER
CHECK OIL PRESSURE
TRANSMITTER
DEFECTIVE? YES
NO
REPLACE MOTOR
INSPECT MOTOR DEFECTIVE? YES
EXCESSIVE SEAL AIR
BLOWING FROM
REGULATOR
WORN OR
DAMAGED
CARBON SEAL?
REPLACE CARBON
SEALS IF > 20 PSIG
YES
TROUBLE #8: Excessive Air From Regulator
TROUBLE #9: Auxiliary Oil Pump Driver Fails to Start
NO
CHECK SEAL ON AIR
REGULATOR
DEFECTIVE?
REPAIR/REPLACE
YES
NO
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-11
NO
NO
NO
REPAIR OR REPLACE
CHECK MAIN OIL
PUMP
DEFECTIVE? YES
REPAIR OR REPLACE
CHECK OIL
PRESSURE
TRANSMITTER
DEFECTIVE? YES
ADJUST, REPAIR OR
REPLACE
CHECK OIL
SYSTEM RELIEF
VALVE IN OPEN
POSITION
DEFECTIVE? YES
AUX. OIL PUMP
MOTOR FAILS TO
SHUT DOWN
DEFECTIVE
CR2 OR CPU
TEST AND REPLACE CR2
OR CPU
YES
AUX. OIL PUMP
MOTOR FAILS TO
SHUT DOWN
TROUBLE #10: Aux. Oil Pump Driver Fails to Shut Down
Troubleshooting Guide R300 / R200 / R150
7-12 visio-chap 7 r150-r200-r300 3-5-08
IMPROPERLY
ADJUSTED CONTROL
VALVES
ADJUST COOLING
WATER FLOW CONTROL
VALVES
YES
NO
REDUCE COOLING
WATER TEMPERATURE
CHECK COOLING
WATER
TEMPERATURE
ABOVE DESIGN?
NO
YES
REPLACE RTD
CHECK OIL
TEMPERATURE RTD
DEFECTIVE? YES
NO
REPLACE AIO
CHECK ANALOG
INPUT MODULE (AIO)
DEFECTIVE? YES
HIGH LUBE OIL
TEMPERATURE
NO
CLEAN OIL COOLER
CHECK OIL COOLER DIRTY? YES
TROUBLE #11: High Lube Oil Temperature
Troubleshooting Guide R300/ R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-13
DEFECTIVE MAIN
OR AUXILIARY OIL
PUMPS? REPAIR OR REPLACE
YES
NO
REPAIR, REPLACE OR
ADJUST RELIEF VALVES
CHECK PUMP RELIEF
VALVES
DEFECTIVE
OR IMPROPERLY
ADJUSTED?
NO
YES
REMOVE OBSTRUCTION
CHECK OIL PUMP
SUCTION LINE
OBSTRUCTED
LINE?
YES
NO
REPAIR LEAK AND PRIME
OIL PUMP
CHECK OIL PUMP
SUCTION LINE
AIR LEAK? YES
LOW LUBE OIL
PRESSURE
NO
REPLACE FILTER
CARTRIDGE
CHECK OIL FILTER
CARTRIDGE
DIRTY? YES
NO
REPLACE OIL PRESSURE
TRANSMITTER
CHECK OIL
PRESSURE
TRANSMITTER
DEFECTIVE? YES
NO
INVESTIGATE PANEL;
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
REPLACE CPU
CHECK CHANNEL ON
CPU MODULE
DEFECTIVE? YES
TROUBLE #12: Low Lube Oil Pressure
CONTINUE TO
NEXT PAGE
NO
Troubleshooting Guide R300/ R200 / R150
7-14 visio-chap 7 r150-r200-r300 3-5-08
TROUBLE #12: Low Lube Oil Pressure
PREVIOUS
PAGE
LOW?
REPAIR LEAKS AND RE-
FILL OIL RESERVOIR.
YES
CHECK LUBE OIL
PRESSURE
WARNING
DISCONNECT POWER TO THE OIL HEATER BEFORE FILLING THE OIL
RESERVOIR WITH OIL. FAILURE TO DO SO MAY RESULT IN SERIOUS OR FATAL
PERSONAL INJURY AND/OR DAMAGE TO COMPRESSOR COMPONENTS.
Troubleshooting Guide R300 / R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-15
CHECK FOR LEAK
OR OBSTRUCTION
REMOVE OBSTRUCTION /
REPAIR LEAKY CONNECTIONS
YES
NO
REPAIR OR REPLACE
ACTUATOR
CHECK INLET VALVE
ACTUATOR
DEFECTIVE?
NO
YES
REPAIR OR REPLACE
LINKAGE
CHECK INLET VALVE
POSITIONING
LINKAGE
BINDING? YES
NO
INLET VALVE FAILS
OR ERRATIC
OPERATION
RE-CALIBRATE OR REPLACE
CHECK I/P
TRANSDUCER
DEFECTIVE? YES
NO
RE-CALIBRATE OR REPLACE
CHECK CURRENT
TRANSMITTER
DEFECTIVE
OR IMPROPERLY
ADJUSTED?
YES
NO
RESET
CHECK SETPOINTS IMPROPERLY SET? YES
PLACE INLET VALVE IN
DESIRE CONTROL MODE
CHECK CONTROL
MODE
INCORRECT MODE? YES
INVESTIGATE PANEL;
CONTACT FS-ELLIOTT;
REPLACE CPU
CHECK CPU DEFECTIVE? YES
INCREASE LINE SIZE TO
3/8" OD COPPER TUBING OR
GREATER
CHECK PNEUMATIC
AIR LINE
TOO SMALL? YES
NO
NO
NO
TROUBLE #13: Inlet Valve / Inlet Guide Vane Failures
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
CHECK FOR AIR
LEAKS OR MOISTURE
IN AIR
YES
NO
Troubleshooting Guide R300/ R200 / R150
7-16 visio-chap 7 r150-r200-r300 3-5-08
CHECK FOR LEAK OR
OBSTRUCTION
REMOVE OBSTRUCTION /
REPAIR AIR LINE
YES
NO
REPAIR OR REPLACE
ACTUATOR
CHECK
UNLOADING
VALVE
ACTUATOR
DEFECTIVE?
NO
YES
REPAIR OR REPLACE
LINKAGE
CHECK
UNLOADING
VALVE
POSITIONING
LINKAGE
BINDING? YES
NO
UNLOADING
VALVE FAILS OR
ERRATIC
OPERATION
INCREASE PRESSURE
CHECK AIR
SUPPLY
PRESSURE
LOW? YES
NO
RE-CALIBRATE OR
REPLACE
CHECK I/P
TRANSDUCER
DEFECTIVE? YES
NO
TROUBLE #14: Unloading Valve Failures
GO TO NEXT PAGE
Troubleshooting Guide R300/ R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-17
RESET
CHECK SETPOINTS
IMPROPERLY
SET?
YES
NO
PLACE UNLOADING
VALVE IN DESIRED
CONTROL MODE
CHECK CONTROL MODE
INCORRECT
MODE?
YES
NO
INVESTIGATE PANEL;
CONTACT FS-ELLIOTT;
REPLACE CPU
CHECK CPU
DEFECTIVE? YES
NO
INCREASE LINE SIZE TO
3/8" OD COPPER
TUBING OR GREATER
CHECK PNEUMATIC AIR
LINE
TOO SMALL? YES
NO
CHECK DISCHARGE
PRESSURE TRANSMITTER
RE-CALIBRATE OR
REPLACE
DEFECTIVE OR
IMPROPERLY
ADJUSTED?
YES
TROUBLE #14: Unloading Valve Failures, continued
CONTACT FS-ELLIOTT FOR
AUTHORIZED DISTRIBUTOR.
CHECK FOR AIR LEAKS OR
MOISTURE IN AIR
YES
NO
PREVIOUS
PAGE
Troubleshooting Guide R300/ R200 / R150
7-18 visio-chap 7 r150-r200-r300 3-5-08
INSUFFICIENT AIR
SUPPLY?
INCREASE AIR SUPPLY
YES
NO
INVESTIGATE PANEL;
CONTACT FS-ELLIOTT;
REPLACE CPU
CHECK ANALOG
OUTPUT CHANNEL
DEFECTIVE?
NO
YES
REPAIR OR REPLACE
VALVE ASSEMBLY
CHECK VALVE
ASSEMBLY
BINDING? YES
NO
LOW OUTPUT
PRESSURE ON UVT,
IVT, FCT, SCT
REPLACE DIAPHRAGM
CHECK DIAPHRAGM RUPTURED? YES
TROUBLE #15: Unloading Valve Transducer (UVT) or
Inlet Valve Transducer (IVT), 1
st
Interstage Temperature
Transducer (FCT) or 2
nd
Interstage Temperature Transducer (SCT)
has low output pressure.
Troubleshooting Guide R300/ R200 / R150
visio-chap 7 r150-r200-r300 3-5-08 7-19
DEFECTIVE
CHANNEL ON
CPU?
INVESTIGATE PANEL;
CONTACT FS-ELLIOTT;
REPLACE CPU MODULE
YES
NO
REPLACE HORN
CHECK HORN DEFECTIVE? YES
HORN FAILS
TO SOUND
TROUBLE #16: Horn Fails to Sound
Troubleshooting Guide R300/ R200 / R150





































































7-20 visio-chap 7 r150-r200-r300 3-5-08
































visio-chap 7 r150-r200-r300 3-5-08