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
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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