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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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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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
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(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
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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
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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
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SEALING
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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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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.