Alemite Carbon Shield CS-5700 Series User manual

Carbon Shield™
Installation,
Operation and
Maintenance
Manual
CS-5700 SERIES

167 Roweland Drive
Johnson City, TN 37601
Toll Free U.S.: 866-4-Alemite
Toll Free Canada: 800-267-8022
International: 803-802-001
Fax U.S.: 800-648-3917
Fax Canada: 800-267-2880
Fax International: 803-802-0192
www.alemite.com

Table Of Contents
1. Introduction .........................................................1
2. Agency Approvals ....................................................2
3. How the Carbon Shield™ (CS) Unit Works ................................3
Oil Mist Density Monitoring ........................................3
4. System Components and Optional Features...............................4
Electrical Control System ..........................................4
AC Power ....................................................4
Enclosure....................................................4
DC Power ....................................................4
Programming Logic Controller (PLC) ...............................4
Human-Machine Interface (HMI)...................................5
HMIPasswordInformation.......................................5
Status Lights..................................................6
Air-Mist Control System ...........................................6
Air Supply Pressure Control ......................................6
Air Solenoid Valve..............................................7
I/P Transducer-Booster Assembly .................................7
Air Heater Package (Optiona Feature) ..............................8
Main Reservoir Assembly ........................................8
Mist Head Assembly ............................................8
Mist Pressure Relief Valve .......................................8
Loader Fitting .................................................9
Oil Heater ....................................................9
OilLevelSensor...............................................9
MistPressureSensor...........................................9
OilVacuumSensor.............................................9
MistOutlet...................................................10
2LO5H¿OO6\VWHP.................................................10
  0DQXDO2LO5H¿OO ..............................................10
  $XWRPDWLF2LO5H¿OO6\VWHP2SWLRQD)HDWXUH .......................10
5. Optional Features....................................................12
Air Heater Package ..............................................12
Back Up Oil Mist Generator (BOMG)................................12
Switching Oil Mist Generation from Main to Backup Unit ...............13
Switching Oil Mist Generation Backup Unit to Main Unit ...............14
Enclosure Cooling System ........................................14
Enclosure Purge System..........................................15
HMI Protective Cover.............................................15
DCS Communication.............................................15

Table Of Contents
6. Accessories ........................................................16
Bulk Oil Storage Tank (BST) .......................................16
Oil Collection Container (OCC).....................................16
Oil Mist Manifold (OMM)..........................................17
Pure Mist Kit (PMK) ..............................................17
Oil Sight Glass (OSG)..........................................17
Purge Mist Kit (PUK).............................................17
Oil Sight Glass (OSG)..........................................18
Drain Leg Kit (DLK)..............................................18
Sun Shield Kit (SSK) .............................................18
7. Installation ........................................................19
Site Preparation .................................................19
Customer Connections ...........................................19
AC Power ...................................................19
Air Supply – Main CS and Backup Units............................19
Air Supply – Bulk Oil Storage Tank (BST)...........................19
Air Supply – Enclosure Cooling System ............................19
Air Supply – Drain Leg Kit (DLK) .................................20
  $XWRPDWLF2LO5H¿OO ............................................20
MistOutlet...................................................20
DCS – Discrete Signal .........................................20
DCS – Serial Communication ....................................20
EnclosureDrain ..............................................20
8. Operation...........................................................21
Before Start-Up .................................................21
Start-Up Procedure ..............................................21
User Name and Password Set Up Procedure .......................22
Date and Time Set Up Procedure.................................24
Other Start /Set Up Considerations .................................25
Level Sensor Calibration........................................25
When Parameter Set Up Required................................26
Set Up Procedure .............................................26
Monitor and Control Features......................................28
Using Change Parameters Feature ...............................28
Using Adaptive Mode Feature....................................29
Monitor and Parameter Values ...................................29
9. Alarms ...........................................................30
Alarm List ......................................................30
Air and Mist Related Alarms .....................................30
Oil Related Alarms ............................................31
OtherAlarms.................................................31
Remote Communication and Alarms................................31
Discrete Alarm Signal ..........................................31
Optional Communication Methods ................................31

Table Of Contents
10. Maintenance Check List..............................................32
11. Troubleshooting Chart...............................................33
6SHFL¿FDWLRQV ......................................................38
13. Spare Parts List ....................................................39
Main Unit.......................................................41
Backup Unit ....................................................42
Turnaround Kit..................................................43
Nozzle Kit ......................................................43
PLC Enclosure and Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
14. Site Preparation ....................................................44
Recommended Enclosure Clearance................................44
Anchor Bolt Hole Pattern .........................................45
15. Wiring Diagrams....................................................46
Main Unit Disconnect Switch ......................................46
Backup Unit Disconnect Switch....................................46
PLC Enclosure Layout............................................47
Digital I/O ......................................................48
Analog I/O......................................................49
Thermocouple Module............................................50
Instrumentation Wiring ...........................................51
Terminal Blocks .................................................52
Modbus RTU Module Connection ..................................53
16. Model Selection Chart ...............................................54
17. Carbon Shield™ General Arrangement Drawing..........................55
18. Carbon Shield™ Typical Installation Drawing............................56

1
1Introduction
Fig. 01 CS Unit with Backup Unit and
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Fig. 02 CS Unit Components
Oil Mist Lubrication is a cost-effective technique for
lubricating gears, chains, rolling element bearings,
sleeve bearings, sliding surfaces and other critical
machinery components. Your new Carbon Shield™
(CS) Oil Lubrication System is the latest technology
in the market for Oil Mist Lubrication.
Every CS unit features carefully selected compo-
nents in a stainless steel enclosure to meet hazard-
ous location requirements in the hydrocarbon in-
dustry. The enclosure and the door-mounted touch
screen display comply with NEMA 4X Standard.
The multi-level password protected Human Ma-
chine Interface (HMI) display panel on the CS unit
offers touch access to a unique combination of ad-
vanced electronics, diagnostics, monitoring, per-
formance parameters and digital communication
interface. Unlike any other system, CS units moni-
tor every parameter and reports warnings to main-
tenance personnel. The system has an adaptive
control mode that learns the operating parameters
and warns against anomalies. Refer to this compre-
hensive manual to guide the installation, operation,
commissioning and maintenance of your Carbon
Shield™ system. Sections are devoted to technical
VSHFL¿FDWLRQVFRPSRQHQWOLVWLQJVDQGDYDLODEOHDF-
cessories and troubleshooting.
Important WARNING and CAUTION notes appear
throughout the guide. See the table of contents for
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and service issues.

2
2Agency Approvals
The Carbon Shield™ unit is UL -Listed under UL
category BAYZ Lubrication-Dispensing Equipment
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(Fig. 03). The lubricants dispensed by this equip-
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BAYZ.E328442
Lubricant-dispensing Equipment for Use in Hazardous Locations
Page Bottom
Lubricant-dispensing Equipment for Use in Hazardous Locations
See General Information for Lubricant-dispensing Equipment for Use in Hazardous Locations
ALEMI TE L L C E328442
1057 521 Corporate Ctr Dr
Fort Mill, SC 29707-7164 USA
Class I , Division 2, Groups B, C and D Hazardous Locations.
Oil Mist Assembly Model 57 followed by 1, 2, 3, 4, 5 or 6, followed by 1, 2, 3, 4, 5 or 6, followed by A or B, followed by A, B or C, followed by A, B
or C, followed by 1, 2, 3, 4 or 5, followed by A or B, followed by A, D or E, followed by 1 or 2, followed by U, followed by A, B or C, followed by 1
or 2.
Last Updated on 2009-04-13
Questions? Print this page Terms of Use Page Top
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under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be Certified and covered under UL's Follow-Up
Service. Always look for the Mark on the product.
UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide
Information, Assemblies, Constructions, Designs, Systems, and/ or Certifications (files) must be presented in their entirety and in a non-
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following format: "© 2015 UL LLC".
Page 1 of 1BAYZ.E328442 - Lubricant-dispensing Equipment for Use in Hazardous Locations
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The CS units are suitable for use in Class I Divi-
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cations.

3
#How the Carbon Shield™ (CS) Unit Works
The Carbon Shield™ system produces a continu-
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WRPUDQJH2LOLVGUDZQIURPDQLQWHJUDOUHVHU-
voir into the mist head where it is atomized into the
air stream.
In order to produce oil mist, dry, instrument-quality
air supplied by the end user enters the console
WKURXJKD¿OWHUUHJXODWRU7KH¿OWHUUHJXODWRUVHSD-
rates any moisture from the air and regulates the
air to an operating pressure that can be used by
the system.
A Programmable Logic Controller (PLC) monitors
the pressure and relays the pressure signals to the
transducer for operational control. Additionally, a
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The incoming air supply may be heated by an op-
tional air heater. Heated air can help maintain the
correct oil/air ratio under cold temperature condi-
tions. The PLC controls air temperature by cycling
the air heater on and off according to signals re-
ceived from the air temperature thermocouple.
The air is then routed to a venturi in the mist head.
The pressure drop produced at the venturi throat
creates a vacuum that lifts oil from the oil reservoir
through the oil pick up tube. There is also a very
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air passes thought the venturi. The impact between
the high speed air stream and the oil coming up
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from the venturi traps the larger oil particles within
the mist and returns them to the reservoir. A trans-
ducer/regulator and PLC control the mist pressure.
The HMI and a pressure gauge (inside the cabinet)
provide visual indication of mist pressure.
The air/oil mist mixture with a smoke-like appear-
ance moves through a piping network at low pres-
sure and low velocity to designated lubrication
points. As the oil mist reaches the lubrication point,
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small dry particles and produce larger wet drop-
lets ideal for the lubrication of bearing surfaces
on gears, chains, rolling element bearings, sleeve
bearings and other key machinery parts.
Oil Mist Density Monitoring
The Carbon Shield™ (CS) units use a proactive ap-
proach to oil mist density monitoring. Unlike current
technology, changes in mist density are predicted
by the control system long before an actual change
in mist density down the stream can be detected.
This prediction is made possible by the use of soft-
ware in the PLC, the HMI, and data from the sen-
sors onboard. These devices work together to con-
tinuously monitor the set points (not the limits) for
DOOWKHSDUDPHWHUVWKDWLQÀXHQFHWKHRLOPLVWGHQVLW\
(i.e. oil-to-air ratio). When a parameter changes
outside its predetermined acceptable range around
the set point, an alarm is issued and the potential
cause is displayed thru the HMI. Therefore, there is
no need for dedicated mist density sensing devic-
es—and their inherent operational issues—to react
to mist density changes.
3

4
#System Components and Optional Features
The Carbon ShieldTM (CS) system consists of three
distinctive systems: the Electrical Control System,
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They interact to produce, monitor and control the oil
mistdelivery to thelubrication point.The followingis
abriefdescription ofeachsystem andtheirfunction.
Electrical Control System
AC Power
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backup units (if backup unit installed) are electri-
cally independent. Therefore, two separate connec-
tions are required: one for the main and one for the
backup unit. In both cases, the end user provides a
FRQGXFWRUFDEOHFDUU\LQJ/1HXWUDODQG*URXQG
connections to each unit. The connection is made
inside the disconnect switch (Fig. 04). See Wiring
Diagram section for details.
Enclosure
The entire Oil Mist Generator (OMG) is housed in a
NEMA 4x stainless steel enclosure. The enclosure
has center-locking, weather-sealed doors with a
three-point locking system. The door is sealed with
“foam in place” gasket and all penetrations to the
enclosure are sealed with gaskets, conduit-sealing
¿WWLQJVRUFDEOHJODQGVDVUHTXLUHGWRPDLQWDLQWKH
NEMA 4x and Hazardous Location ratings.
DC Power
Housed in a secondary NEMA 4x enclosure, a
jumper-selectable DC power supply transforms in-
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and various sensors and control devices. The jump-
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Wiring Diagram).
Programmable Logic Controller (PLC)
Alsocontained inthe secondaryNEMA4Xelectrical
enclosure are the PLC and digital as well as analog
modules which provide the monitoring and control
functions of the Carbon Shield™ system (Fig. 05).
The PLC also provides the information displayed
on the HMI such as system status, parameter val-
ues and alarm conditions. The analog and digital
I/O on the PLC features small LED lights that turn
on when the channel is energized. This feature is
very helpful when troubleshooting a problem.
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WARNING
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4
Fig. 04 Power Disconnect Switch
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DISCONNECT
SWITCH
CONDUIT
SEALING
FITTING

5
#System Components and Optional Features
4
The PLC receives Input signals from:
• 0LVW3UHVVXUH6HQVRU$QDORJP$
• 2LO9DFXXP6HQVRU$QDORJP$
• Air Temperature Thermocouple (Type J)
• Oil Temperature Thermocouple (Type J)
• 2LO/HYHO6HQVRU$QDORJP$
The PLC sends Output signals to:
• ,37UDQVGXFHU5HJXODWRU$QDORJP$
• Digital I/O for Interposing Relays for:
• Air Heater
• Oil Heater (Main unit only)
• $XWRPDWLF2LO5H¿OO6ROHQRLG
• Air Solenoid
• Local Status Red Light (Alarm)
• Local Status Green Light (System OK)
• DCS DiscreteAlarm Signal
• HMI to display alarms and operational
parameter status.
Human Machine Interface (HMI)
The touch screen HMI on the door of the CS unit
enclosure provides a color visual display of system
status, parameter values and alarm conditions (Fig.
06). The HMI is also the access port for set up and
programming of the system parameters at start up.
The HMI is connected to the PLC by a serial com-
munication cable.
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Home Screen
HMI Password Information
User names and passwords are assigned through
the HMI. They allow the appropriate access to the
two password protected screens in the HMI. Level
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8SDQG&KDQJH3DUDPHWHUVVFUHHQV7KH/HYHO
password access is limited to the Change Param-
eters screen only. All other screens in the HMI are
viewing/information and do not require a password.
For more information see User Name and Password
Setup Procedure section.
Whenever a password protected screen is attempt-
ed to be accessed, a pop up window will come up
to allow the user to enter the user name and pass-
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user or password, a key board screen is retrieved.
This touch key board has the same functionality as
a standard PC key board.
Once the user name or password is typed in, press
the return/enter key to hide the key board and re-
turn to the pop up window. When the user name
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button to go back to the desired password protect-
ed screen. Here the user has one minute to access
the intended password protected screen before the
access is again denied and the password has to be
re-entered.

6
#System Components and Optional Features
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4
Status Lights
Red and Green Status (LED type) indicator lights
are mounted on the top of each CS unit cabinet
(Fig. 07). The status lights are controlled by the
PLC. The green LED is illuminated when the sys-
tem is operating normally and all operating param-
eters fall within the expected range. The red LED
ÀDVKHVZKHQDQ\DODUPFRQGLWLRQVRFFXUVRUGXU-
ing system setup. The alarms are also displayed
on the HMI Current Alarm screen. The red LED will
automatically turn off and the green turns back on
only when all alarm conditions have been restored
to their acceptable parameter values.
Air-Mist Control System
Air Supply Pressure Control
The customer-supplied, instrument-quality air con-
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$60(%VWDLQOHVVVWHHOÀDQJH(Fig. 08) From
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and a moisture separator with automatic drain (Fig.
09). The pressure gauge allows the user to view the
inlet pressure and to set the incoming air pressure
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start-up.
AIR SUPPLY
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7
4System Components and Optional Features
Air Solenoid Valve
TheAir Solenoid Valve is next downstream from the
air regulator (Fig. 10). This solenoid protects the I/P
transducer regulator from receiving air pressure
while the PLC and control electronics are not en-
ergized and therefore not in control of the system.
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Vacuum Sensors
I/P Transducer-Booster Assembly
Next in line is the I/P Transducer-Booster assem-
bly. Its function is to regulate the inlet pressure
such that the mist pressure is kept constant at all
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mist pressure sensor and provide feedback to the
I/P Transducer-Booster (Fig. 11).
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tors with a visual indication of the mist pressure.
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available in the cabinet (Fig. 11 & Fig. 12).
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MIST PRESSURE SENSOR
VACUUM SENSOR
OIL SOLENOID
AIR SOLENOID

8
4System Components and Optional Features
Air Heater Package (optional Feature)
The Air Heater Package is an optional but popular
feature. When installed, the pressure-regulated air
from the I/P Transducer-Booster passes through
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& 7KH WHPSHUDWXUH FRQWURO LV DFKLHYHG
based on the input from a thermocouple mounted
close to the mist head inlet port . The PLC switches
the corresponding relay so the air heater cycles ON
and OFF. The air heater has an internal thermostat
that is used as over temperature cut off control in
case of PLC or electronic failure. The thermostat is
VHWWR)WKHIDFWRU\DQGLVQRWDGMXVWDEOH
Main Reservoir Assembly
Main Reservoir Assembly features a stainless steel
oil reservoir where the oil for mist production is
stored (Fig. 13). The mist head assembly and the
oil level sensor are attached to the top of the tank.
The oil heater and oil temperature thermocouple
are also part of the tank assembly and located on
opposite sides of the tank. Other components of the
assembly include the mist pressure gauge, oil ther-
mometer and oil level indicator/gauge. There is also
a clean out door on the front face of the reservoir for
ease of reservoir maintenance.
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Mist Head Assembly
The air from the air heater enters the mist head at-
tached on top of the tank. Inside the mist head, the
oil mist is produced. The mist assembly contains
a mist nozzle, nozzle O-ring, crunch gasket, mist
head O-ring, oil pickup tube and mesh oil strainer. It
is recommended that the O-rings and crunch gas-
ket are replaced whenever the mist heat is uninstalled
or serviced.
Other components of the Mist Head Assembly are:
Mist Pressure Relief Valve
The Mist Pressure Relief Valve is located on the left
side of the mist head (Fig. 14). The valve begins to
RSHQDWDSSUR[LPDWHO\SVLNJFPDQGIXOO\
RSHQVVKRXOGPLVWSUHVVXUHULVHWRSVL*HQHU-
ally, if there is close-to-total block of the mist outlet,
this occurs almost instantaneously.

9
4System Components and Optional Features
Oil Level Sensor
The Oil Level Sensor detects change in oil level as
a function of change in capacitance between sen-
sor probe and the shield as oil level changes. The
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PLC for reservoir oil level control and oil consump-
tion calculations (Fig. 12).
Mist Pressure Sensor
The Mist Pressure Sensor mounts on the PLC box
(Fig. 10) and connects to the top of the reservoir by
rigid tubing (Fig. 12). The mist pressure sensor pro-
YLGHVP$DQDORJVLJQDOWRWKH3/&WRPRQLWRU
the oil mist pressure. The PLC uses this informa-
tion and provides feedback to the I/P Transducer-
Booster to keep the mist pressure always constant.
The oil mist pressure is displayed on the Parameter
Value screen on HMI (Fig. 15). In addition, a pres-
sure gauge allows the operator to view the actual
oil mist pressure right on the tank assembly (Fig.
12).
Oil Heater
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:DWWVDW9$&RU9$&GHSHQGLQJRQWKHDS-
plication. The oil heater is located on the lower right
hand side of the oil reservoir (Fig. 14.a). The heat-
ing element area in contact with the oil is such that
allows for a slow release of heat at watt density of
:LQPDLQWDLQLQJWKHRLOSURSHUWLHVLQWDFWDVWKH
heater cycles on and off. Both the main and back
up units use the same type of oil heater. The inter-
nal thermostat is used as over temperature cut off
control in case of PLC or electronic failure. In the
case of the back-up/auxiliary unit, the thermostat
is used to control the oil operating temperature. In
both cases, the thermostat is set from the factory
and generally no further action is required.
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Loader Fitting
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mist head allows oil to be added to the reservoir
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WKHRSWLRQDODXWRPDWLFUH¿OOSDFNDJHLVQRWSXU-
chased (Fig. 14).
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Oil Vacuum Sensor
TheOil Vacuum Sensor is also mounted on the PLC
box and connected to the top of the mist head by
rigid tubing (Fig. 10 and Fig. 14),WVHQGVP$
analog signal to the PLC to monitor the oil vacuum
produced by the venturi. The PLC monitors so that
the value of oil vacuum does not change once the
XQLWVHWXSKDVEHHQFRQ¿UPHGRUDIWHUWKH$GDSWLYH
Mode feature has been used.

10
4System Components and Optional Features
Mist Outlet
Once the mist is produced in the mist head, trav-
els through the Mist Outlet on the reservoir and
out to the distribution/header lines. The customer
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% VWDLQOHVVVWHHO ÀDQJH SURYLGHG RQ WKH RXW-
side of the enclosure. (Fig. 16.a and Fig. 16.b).
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2LO5H¿OO6\VWHP
0DQXDO2LO5H¿OO
The oil level on the CS reservoir on both the main
DQGEDFNXSXQLWVFDQEHUHVWRUHGE\PDQXDOO\¿OO-
ingthe tankusing anAlemite Bucket Pumppackage
$OHPLWH317KHSXPSSDFNDJHLQFOXGHV
DKRVHDQGVSHFLDOORDGHU¿WWLQJ7KHORDGHU¿WWLQJ
RQWKHKRVHLVGHVLJQHGWRFRQQHFWWKHORDGHU¿W-
ting on the front face of the mist head (Fig. 14). The
PDQXDOUH¿OORSHUDWLRQLVSHUIRUPHGZLWKRXWDIIHFW-
ing the oil mist production and distribution. The oil
OHYHOVKRXOGDOZD\VEHPDLQWDLQHGDERYHWKHJDO-
ORQOLWHUVPDUNRQWKHRLOOHYHOJDXJHORFDWHG
on the front face of the oil reservoir assembly (Fig.
13). If the oil level on the main unit reservoir drops
EHORZWKHJDOORQVOLWHUVDVPHDVXUHGE\
the oil level sensor, the PLC will issue an alarm.
There are no alarms for the backup unit. Therefore,
careful attention to the oil level in the back up unit
reservoir by the end user is required.
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(optional feature)
7KH$XWRPDWLF2LO5H¿OOV\VWHPLVDQRSWLRQDOIHD-
tureand requiresa bulkoil storagetank witha pump
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sories section) designed to work with the CS unit.
The bulk oil system outlet connects to the Auto-
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$60(%VWDLQOHVVVWHHOÀDQJHDWWDFKHGWRD
PLFURQRLO¿OWHUDVVHPEO\RQWKHOHIWVLGHRIWKHHQFOR-
sure (Fig. 17).
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2XWVLGHRI(QFORVXUH
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11
System Components and Optional Features
4
Filtered oil enters the reservoir of the main genera-
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HQHUJL]HGE\WKH 3/& LQ UHVSRQVH WR DQ ³RLO UH¿OO
required” signal from the level sensor. The current
“useful” amount of oil in the main reservoir is dis-
played through the Parameter Values screen on the
HMI (Fig. 15). In addition, the oil level sight glass on
the oil reservoir provides operators a visual indica-
tion of the resulting oil level (Fig. 1).
'RZQVWUHDPIURPWKHRLO¿OWHUDVKXWRIIYDOYHLQ-
side the main enclosure is provided (Fig. 18). This
valve must always be in normally open (NO) posi-
WLRQH[FHSWZKHQXVHGWRLVRODWHWKHRLOUH¿OOVROH-
noid for repair or service.
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,Q &6 XQLWV ZLWK EDFNXS XQLW DQG DXWRPDWLF UH¿OO
package options installed, the oil level in the back-
up reservoir can be restored by opening the manual
ball valve inside the backup unit enclosure. While
UH¿OOLQJWKLVZD\VWRSWKHUH¿OOE\FORVLQJWKHYDOYH
when the oil is around the 4 gallon mark on the sight
JODVV/HDYLQJWKHRLOOHYHOEHWZHHQJDOORQVRQ
the back up reservoir is enough for the backup unit
to perform its function. If the oil level goes above
WKHJDOORQPDUNRQWKHRLOOHYHOJDXJHWKHH[FHVV
oil must be drained.
There is a drain valve on the bottom side of the res-
ervoir that drains the oil through the enclosure drain
port directly below the reservoir (Fig. 19). Simply re-
move the enclosure drain port cap from outside of the
enclosure to before opening the reservoir drain valve.
IMPORTANT NOTE:
7KHHQFORVXUHGUDLQSRUWFDSPXVWEHUHLQVWDOOHGDIWHU
WKHGUDLQRSHUDWLRQLVFRPSOHWHG
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12
Optional Features
5
Some of the optional features in this section have
already been mentioned above. This section pro-
vides more detailed information on their compo-
nents and function.
Air Heater Package
The Air Heater Package is an optional but popular
feature. When installed, the pressure-regulated air
from the I/P Transducer-Booster passes through
WKHDLUKHDWHUWRPDLQWDLQDLUWHPSHUDWXUHDW)
& 7KH WHPSHUDWXUH FRQWURO LV DFKLHYHG
based on the input from a thermocouple mounted
close to the mist head inlet port (Fig. 20). The PLC
switches the corresponding relay so the air heater
cycles ON and OFF. The air heater has an inter-
nal thermostat that is used as over temperature cut
off control in case of PLC or electronic failure. The
WKHUPRVWDWLVVHWWR)WKHIDFWRU\DQGLVQRWDG-
justable.
Two sizes of air heaters are available:
8QLWVZLWK&)0&)0DQG&)0QRPL-
QDOPLVWFDSDFLW\UHTXLUHD:DWWDLUKHDWHU
 8QLWV ZLWK  6&)0  6&)0 DQG  6&)0
QRPLQDOPLVWFDSDFLW\UHTXLUHD:DWWDLUKHDW-
er.
Backup Oil Mist Generator (BOMG)
The BOMG is a highly recommended option.
The BOMG should only be used for temporary
situations such as maintenance or repair to the
main CS unit. The BOMG is mounted inside a
NEMA 4X enclosure of the same material as
the enclosure of the main generator. It comes
fully equipped with its own air pressure regu-
lator. The reservoir assembly contains an oil
mist head assembly with the oil mist genera-
tion capacity as the main unit’s.
The mist pressure on the BOMG is set by gen-
tly turning the knob on the air regulator while
observing the mist pressure gauge until it
VKRZVWKHPLVWSUHVVXUHWREHLQ+2
The BOMG is electrically independent from
the main unit. A separate ON/OFF switch lo-
cated on the right side of the enclosure. The
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PDLQXQLW7KHHQGXVHUSURYLGHVDFRQGXF-
WRUFDEOH/1HXWUDODQG*URXQGUXQWRWKH
BOMG. The connection is made inside the dis-
connect switch (see Wiring Diagram).
The oil heater for the BOMG is controlled by
its internal thermostat. The temperature set-
WLQJ)&LVGRQHDWWKHIDFWRU\DQG
under normal operating conditions, no further
action is required.
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0DQXDO 2LO 5H¿OO VHFWLRQ RU VHPLDXWRPDWLF
from the bulk storage tank if the optional auto
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¿OOVHFWLRQ
Important Note:
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WHQWXVHRQO\:KHQRSHUDWHGIRUSXUSRVHVRWKHUWKDQ
SHUIRUPLQJPDLQWHQDQFHURXWLQHZRUNRQWKHPDLQ
XQLWWKHEDFNXSXQLWVKRXOGEHFKHFNHGDWWKHEHJLQ
QLQJRIHYHU\VKLIWDVDYHU\PLQLPXP
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AIR THERMOM-
ETER
AIR
TEMPERATURE
THERMOCOUPLE
AIR HEATER

13
5Optional Features
Switching Oil Mist Generation from Main to
Backup Unit
Follow the steps below to switch the oil mist gen-
eration from the main CS unit to the BOMG.
(QVXUH WKDW WKH %20* KDV DW OHDVW  JDOORQV
 OLWHUV RI RLO DV LQGLFDWHG E\ WKH RLO OHYHO
sight glass.
(QVXUHWKHSRZHUVZLWFKRQWKH%20*LVWXUQHG
to ON position.
&KHFN WKDW WKH WHPSHUDWXUH RI WKH RLO LQ WKH
UHVHUYRLULVDWOHDVWDW)&
4. With the main CS unit still running, open the
LQ EDOO YDOYH RQ ORFDWHG RQ WRS RI WKH %20*
enclosure. Alarms may be issued by the PLC on
the main CS unit at this point (Fig. 21).
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*RWRWKHOHIWVLGHRIWKHPDLQ&6HQFORVXUHDQG
change the direction of the air supply towards the
backup unit by turning the handle on the air di-
verter valve (Fig. 22).
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2SHQWKHPDLQHQFORVXUHDQGWXUQWKHSRZHUGLV-
connect switch to the OFF position. All electrical
devices in the main CS unit should now be OFF.
However, the main reservoir is still pressurized
with oil mist now coming from the BOMG.
7. Go to the right side of the main CS unit enclo-
VXUH DQG FORVH WKH LQ EDOO YDOYH RQ WKDW VLGH
of the enclosure. This valve is located just under
WKHLQWHHLQYHUWLFDORULHQWDWLRQ(Fig. 23). After
this step, the mist pressure gauge on the main
CS unit reservoir may still show some residual
LQ+2PLVWSUHVVXUH7KLVUHVLGXDOSUHVVXUHPD\
be released by pulling the ring on the pressure
relief valve located on the left side of the mist
head.
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7KH%20*LVQRZJHQHUDWLQJWKHRLOPLVWLQWKH
system.
 &KHFN WKH PLVW SUHVVXUH RQ WKH PLVW SUHVVXUH
gauge on the BOMG. Adjust the mist pressure to
LQ+2PP+2LIQHFHVVDU\$GMXVWPHQW
to the mist pressure in the BOMG is done by gen-
WO\WXUQLQJWKHDLU¿OWHUUHJXODWRUNQREZKLOHZDVK-
ing the mist pressure value on the mist pressure
gauge.

14
5Optional Features
Switching Oil Mist Generation Backup Unit
to Main Unit
Follow the steps below to switch the oil mist
generation from the Backup to the Main Unit.
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right side of the main CS unit enclosure and
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XQGHUWKHLQWHHLQYHUWLFDORULHQWDWLRQ(Fig. 23).
After this step, the mist pressure gauge on the
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pressure gauge on the backup unit). But the
BOMG is still the one producing oil mist.
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Alarms will be present on the HMI.
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change the direction of the air supply towards
the main CS unit by turning the handle on the air
diverter valve (Fig. 22). The main unit will start to
make mist.
4. Open the BOMG enclosure and turned the pow-
er disconnect switch to the OFF position. The oil
heater in the backup unit should now be OFF.
However, the reservoir is still pressurized with oil
mist now coming from the main CS unit.
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the BOMG enclosure (Fig. 21). Now the main
CS unit is producing oil mist. After this step, the
mist pressure gauge on the backup unit reser-
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pressure. This residual pressure may be re-
leased by pulling the ring on the pressure relief
valve located on the left side of the mist head.
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automatically to the last set point in the PLC be-
fore it was turned off.
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pected at this point. Check the entire system to
ensure enough lubricant is getting to all lubrica-
tion points.
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system lubrication issues were found, the adap-
tive mode feature should be used to clear those
alarms.
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present) will go away as soon as their actual
values reach their set point values stored in
the PLC before it was turned off.
Enclosure Cooling System
An optional Enclosure Cooling System is available
for Carbon Shield™ unit when the unit is installed in
high ambient temperature conditions. It operates in
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ditions inside the main CS unit enclosure (Fig. 24).
The cooling unit directs chilled air into the main
CS unit enclosure to maintain the internal tem-
perature within the operating limits of the various
electronic controls. This is not an electrical device.
One bulb-an-capillary thermostat per stage con-
trols the air temperature. The thermostats are fac-
tory set to maintain the enclosure temperature be-
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The cooling unit requires instrument-quality com-
pressed air.
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15
Optional Features
5
Enclosure Purge System
The Enclosure Purge system is an optional feature
recommended for highly contaminated areas. The
system requires clean, dry, compressed instrument
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reduceentryofcontaminants to theenclosure(Fig.24).
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HMI Protective Cover
The HMI protective cover (Fig. 25) is a very conve-
nient option to protect you equipment. The cover
consists of a NEMA 4x, stainless steel cover that
is installed on the main enclosure door to protect
the HMI from the weather and impact damage from
rocks, sand or other forms. The HMI can be viewed
through a clear window or accessed by opening the
cover’s hinged door (Fig. 25a).
DCS Communication
Alemite offers optional communication capabilities
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or Modbus TCP/IP (Ethernet). In all cases the unit
communicates using standard Modbus RTU proto-
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Holding Registers). Alemite supplies a Modbus
memory map of the operating variables and alarms.
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SUN
SHIELD
HMI
PROTEC-
TIVE COVER