HushAir Connect 7500 COMPRESSOR SYSTEM User Guide 087-0067 Rev A
HushAir Connect 7500 User Guide COMPRESSOR SYSTEM 087-0067 Rev A
© 2016 Scott Safety. SCOTT, the SCOTT SAFETY Logo, Scott Health and Safety, Protege, Proton, Scout, Freedom, Masterdock, Meridian are registered and/or unregistered marks of Scott Technologies, Inc. or its affiliates. All rights reserved. No part of this documentation may be reproduced in any form or by any means or used to make any derivative work (such as translation, transformation, or adaptation) without written permission from Scott Safety.
087-0067 Rev A CONTENTS About This Guide Guide Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Guide Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Related Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II CONTENTS CO Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS III Appendix Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Technical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV CONTENTS 087-0067 REV A SCOTT SAFETY
087-0067 Rev A LIST OF FIGURES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 SCOTT SAFETY Compressor Major Parts Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Charge Station Major Parts Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Storage Unit Major Parts Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Wiring Overview - System . . . . . . . . . . . . . . . . . .
VIII LIST OF FIGURES 41 42 43 44 45 46 47 48 087-0067 REV A Condensate Container Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Saver Button Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Button Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet Filter Location . . . . . . . . . . . . . . . . .
087-0067 Rev A LIST OF TABLES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 SCOTT SAFETY Scott Safety Documentation Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Hush Air Connect 7500 User Guide Revision History . . . . . . . . . . . . . . . . xiv Certifications and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Compressor System Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X LIST OF TABLES 087-0067 REV A SCOTT SAFETY
087-0067 Rev A ABOUT THIS GUIDE Guide Overview This guide describes the steps required to use the Hush Air Connect 7500, the Revolve Air Connect and the Smart Touch Controller. This document is for Operator and Supervisor level personnel to manage their system. This document contains information on configuration, operation, maintenance and troubleshooting. This user guide assumes a basic knowledge of high pressure procedures.
XII ABOUT THIS GUIDE Guide Conventions The following visual elements are used throughout this guide, where applicable: Warning: This icon and text indicate a potentially hazardous situation, which, if not avoided, could result in death or injury. Caution: This icon and text indicates a potentially dangerous procedure. Instructions contained in the warning must be followed. Failure to do so may result in damage to the device.
Related Product Documentation Related Product Documentation xiii Table 1 lists the Scott Safety Family documentation set.
XIV ABOUT THIS GUIDE Revision History Table 2 shows the revision history for this guide, providing a description of the changes.
Certifications and Approvals Certifications and Approvals xv Table 3 shows the units has been tested and complies with the following directives, standards, or standardized documents. . Table 3 Certifications and Approvals SYMBOL SPECIFIC DIRECTIVES, STANDARDS CAN/CSA-C22.2 No. 68-09 Motor-Operated Appliances Household and Commercial UL 1450 3rd Edition Motor Operated Aire Compressors, Vacuum Pumps and Painting Equipment.
XVI ABOUT THIS GUIDE Table 3 Certifications and Approvals (continued) SYMBOL SPECIFIC DIRECTIVES, STANDARDS FCC Part 15 Class B International Radio-Frequency Devices Note: This approval only applies to devices with RF capabilities. FCC Compliance Statement (Part 15.19) This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2.
General Safety Information General Safety Information xvii Ensure you adhere to the following for your safety. Warning: Read and follow the entire content of this guide prior to use. Failure to do so may result in serious injury or death. Warning: All individuals who have or will have responsibility for using or testing this product must read and understand the contents of this manual. The product will perform as designed only if used and tested in accordance with the manufacturer's instructions.
XVIII ABOUT THIS GUIDE Caution: If this equipment does not operate as described in these instructions, do not use the equipment. Follow your procedures to remove the equipment from service including any “Lock-out/Tag-out” procedures to prevent use of the equipment. Contact authorized personnel to inspect and service the equipment. Warning: This equipment must be operated and serviced by qualified personnel only. Read and understand the guide completely before operating or servicing.
Warnings and Cautions – Working with Compressed Air Warnings and Cautions – Working with Compressed Air xix Ensure you follow the applicable warnings and cautions indicated here. Warning: Before use, this equipment must be properly installed and inspected by a Scott Safety trained and certified technician. Do not operate if the equipment has not been prepared by a Scott authorized service technician.
XX ABOUT THIS GUIDE Warning: Never perform any service on this equipment unless the electric power is switched Off at the main terminal, the compressor is completely stopped, and all residual air pressure has been released from the system. Follow the recommendations of the OSHA Lock Out/Tag Out procedures. Warning: Never pass in front of an air outlet when compressed air is being released. High pressure air could cause injury.
087-0067 Chapter 1 Rev A INTRODUCTION Chapter Overview This chapter covers the following topics: • • SCOTT SAFETY Overview Theory of Operation 087-0067 REV A
2 CHAPTER 1: INTRODUCTION Overview The air breathing system is a configurable system built based on your specific application needs. In general, the system may be made up of a maximum of four major components that include: a compressor, a charge station, HMI, and storage. Additionally, based on your needs, either single component may be used as a standalone device. The HushAir Connect 7500 is the compressor, the RevolveAir Connect is the charge station and the SmartTouch Controller is the HMI.
Overview 3 Table 4 lists the available system compressor categories. Table 4 Compressor System Categories LCD SYSTEM WITH PSI CATEGORY STAGES HMI OUTPUTS HP MOTOR PURIFICATION FILTERS OPTION Standard Five Yes 6K to 7K 7.5, 10, 15, 20 208VAC/1P H/60Hz 208VAC/3P H/60Hz 230VAC/1P H/60Hz 230VAC/3P H/60Hz 380VAC/3P H/50Hz 440VAC/3P H/50Hz 460VAC/3P H/60Hz 2 for 7.5 to 10HP 3 for 15HP 4 for 20HP Motor Saver Quiet Five Yes 6K to 7K 7.
4 CHAPTER 1: INTRODUCTION Figure 1 Compressor Major Parts Example 15 14 10 13 16 17 9 18 1 12 19,20 21 11 22 8 7 6 2 3 4 5 Table 5 lists the major parts of a compressor example. Table 5 Compressor Major Parts Example REFERENCE NUMBER ITEM* 087-0067 REV A 1 Purification Filters - Each filter cleans the air for that specific compressed air stage in the cycle. Removes oil, moisture and debris. The actual number of purification filters depends on the Horse Power of the motor. 7.
Overview 5 Table 5 Compressor Major Parts Example REFERENCE NUMBER ITEM* 6 Electrical Box - Contains all the electrical circuits needed for the motor/compressor running and PLC power supply. 7 440/220VAC Power Connection - Supplies VAC to the device. 8 Fuses - Two (2) fuses that protect the electrical circuits. 9 E-Stop - Manually shuts down the compressor. 10 Horn - Alarms indicating important events 11 Oil Drain - To drain oil when required.
6 CHAPTER 1: INTRODUCTION Table 6 lists the available charge station models.
7 Overview Figure 2 Charge Station Major Parts Example 18 19 13 1415 16 17 20 21 12 11 1 10 9 2 3 4 2 3 4 5 8 22 7 6 Table 7 lists the major parts of a charge station example. Table 7 Charge Station Major Parts Example REFERENCE NUMBER ITEM* SCOTT SAFETY 1 LCD - User interface via the HMI. 2 Charge Adapter (2) - Connection to cylinder. 3 RFID Cylinder - Reads cylinder data and record into log. 4 Proximity Sensor - Detects the cylinders. 5 Camber Door - Allows rotation.
8 CHAPTER 1: INTRODUCTION Table 7 Charge Station Major Parts Example REFERENCE NUMBER ITEM* 13 Schrader Valve - To calibrate CO. 14 Manual Air Valve On/Off Knob - Allows air pressure from either the compressor or the storage to the charge station. 15 Schrader Valve - To take sample of air. 16 E-Stop - Manually shuts down the compressor. 17 Horn - Alarms indicating important events. 18 Analog Gauge - Displays the air pressure going to DP sensor that monitors the Dew Point.
Overview 9 Figure 3 Storage Unit Major Parts Example 1 1 2 3 2 4 4 5 5 3 Table 9 lists the major parts of a storage example. Table 9 Storage Major Parts Example REFERENCE ITEM* NUMBER 1 Manual Air Flow On/Off Knob - To control the air flow pressure. 2 Analog Pressure Gauge - Displays actual pressure of the storage cylinder. 3 Automatic Relief Value - To control or limit the pressure. 4 Cylinder - Vertical mounted available in either 2 or 4 configurations.
10 CHAPTER 1: INTRODUCTION Theory of Operation This section covers the theory of operations of the system. The purpose of the Air Breathing System is to produce breathing air that meets Grade D/E of the CGA breathing air standard G-71 and National Fire Protection Association (NFPA) 1989. The production of high-pressure breathing air can be divided into four (4) categories: • Compression - Air compression is accomplished using a multi-stage compressor assembly. This is performed by the Compressor unit.
087-0067 Chapter 2 Rev A INSTALLATION Chapter Overview This chapter covers the following topics: • • • • SCOTT SAFETY Planning for Installation Installation Checklist Locating and Securing the Devices Wiring the Devices 087-0067 REV A
12 CHAPTER 2: INSTALLATION Planning for Installation Verifying Items Shipped Following Electrical Codes This section provides the pre-installation items. This section provides a list of the items that ship with the device. Ensure you have all items, if not See “Technical Service” on page 92. • Compressor, Charge Station, Storage Unit (varies based on customer specific order) • User Guide on CD This section provides information about adhering to electrical codes when installing the device.
Installation Checklist Installation Checklist 13 This section provides the installation requirements. Table 10 lists the individual items. Table 10 Installation Checklist ITEM ACTIVITY DETAILS Charge Station Locating See “Locating the Charge Station” on page 14. Securing See “Securing the Charge Station” on page 14. Wiring See “Wiring the Charge Station” on page 17. Installation See “Installing the RFID Read/Write Scanner” on page 17. See “Installing the RFID Read/Write Software” on page 18.
14 CHAPTER 2: INSTALLATION Locating and Securing the Devices Locating the Charge Station This section covers locating and securing the devices. Depending on the specific customer order the devices may vary. This section covers the selection of a proper location for the Charge Station. Warning: Make sure there is nothing close to or on top of the Charge Station that could interfere with normal operations.
Locating and Securing the Devices 15 be established at installation on all sides and above the Compressor and must be maintained. Warning: Make sure nothing is operating in the vicinity of the Compressor air intake which might contaminate fresh air supply. Such as: vehicle exhaust, chimney smoke, ventilator fumes, or other source of contamination. Securing the Compressor Securing the Storage Unit This section covers securing the Compressor. The Compressor is equipped with 4 adjustable feet.
16 CHAPTER 2: INSTALLATION Wiring the Devices This section covers wiring the various devices. Specifically, Figure 4 shows an overview of the required power to be supplied by the end user for the system. Caution: This product has more than one connection to the source of supply. To reduce the risk of electrical shock, disconnect all such connections before servicing. This product must be connected to a ground, metallic, permanent wiring system, or an equipment-grounding terminal or lead on the product.
Wiring the Devices Wiring the Charge Station 17 This section covers the wiring the Charge Station. Figure 5 shows the required power to be supplied by the end user for the Charge Station.
18 CHAPTER 2: INSTALLATION Table 11 RFID Read/Write Scanner Parts REFERENCE NUMBER ITEM* 4 Installing the RFID Read/Write Software USB Cable - Provides both signal and power between RFID Read/Write Scanner and the PC. This section covers the installation of the RFID Read/Write Software. After loading the RFIDreader.exe file onto a PCs drive, double click and an icon appears on the desktop. See Figure 7. Not all models support the RFID functions and thus this section may or may not be applicable.
Wiring the Devices Wiring the Compressor 19 This section covers the wiring the Compressor. Figure 8 shows the required power to be supplied by the end user for the Compressor.
20 CHAPTER 2: INSTALLATION 087-0067 REV A SCOTT SAFETY
087-0067 Chapter 3 Rev A CONFIGURATION AND SETUP Chapter Overview This chapter covers the following topics: • • • • • • SCOTT SAFETY Using the HMI User Access Levels Using the Compressor HMI Using the Charge Station HMI Configuring the System Using the RFID Read/Write Software 087-0067 REV A
22 CHAPTER 3: CONFIGURATION AND SETUP Using the HMI The HMI screen is the interface through which various levels of operators can monitor important parameters and configure, the compressor, and/or charge units of the system. When any parameter values are out of normal operating range, the HMI outputs alerts to the user, suggest possible actions or shutdown the unit depending on the severity of the alert condition.
User Access Levels User Access Levels 23 This section covers the access levels. Access into the HMI is either by RFID card or entering passcode. After successful logon the user’s name and the role type is displayed. This allows proper access to specific areas based on the role.
24 CHAPTER 3: CONFIGURATION AND SETUP allowable overrides, set system units, location and time, set system language, review alarm data, and view maintenance and history schedules, as well as, enable remote operation of the compressor by a service technician. These items collectively involve configuration. See “Configuring the System” on page 38. • User: This user is a individual trained and designated by the customer’s supervisor as authorized to operate the system.
Using the Compressor HMI Using the Compressor HMI 25 The HMI has a compressor screen that displays a color-coded quick view of the system and provides access various functions. See Figure 10. Figure 10 HMI Compressor Screen SCOTT SAFETY • Auto - The compressor may be operated in one of two modes. The modes are Automatic or Manual. In the Auto mode, the compressor starts and runs until the pressure switch is tripped at 7000PSI and the automatically restarts when the pressure drops to 6200PSI.
26 CHAPTER 3: CONFIGURATION AND SETUP • Drain - The HMI automatically determines when to perform a drain and the length of time of the drain based on the factory defaults. Factory default for the drain interval: 15Mins. The default for the length: 15Secs. A drain may be manually performed when the user selects the Drain button. • • Silence - Manually disables the horn(s) on the compressor. • • Logout - Exists and returns to the pass code/scan card screen.
Using the Compressor HMI 27 .
28 CHAPTER 3: CONFIGURATION AND SETUP Table 12 Alerts with Override Default Settings - Compressor (continued) ITEM MEASUREM ENT RANGE ALARM TIME DELAY RANGE Opera 7500psig tion Pressu re Max 0 to 120Sec CO2 0 to 5% O2 H2S TIME ALARM ALARM ALARM DELAY WARNING SHUTDOWN STATES HORN ALARM 50Sec OVERRI DE COOL MANUAL MAX.
Using the Compressor HMI 29 . Table 14 Information Types - Compressor ITEM UNITS Total hours of run time: Hrs/Min Hour meter Hrs/Min Hours remaining on purifier filter Hrs/Min CO sensor installation date MM/DD/YY DP sensor installation date MM/DD/YY CO calibration date MM/DD/YY • Checklists - Displays applicable information based on either standalone of a compressor or charge station or a combination. Typically this covers the pre-operation checklist.
30 CHAPTER 3: CONFIGURATION AND SETUP conform to the National Electric Code, and must comply with all State and local codes and regulations. Use of incorrect electrical power input may permanently damage the equipment and could cause serious injury or death to the user. 33339 Table 15 Pre-Operation Checklist - Compressor 087-0067 REV A ITEM ACTIVITY FREQUENCY DETAILS Maintenance schedule Verify Before each operation Verify that the maintenance schedule is up to date for the unit.
Using the Compressor HMI 31 Table 15 Pre-Operation Checklist - Compressor ITEM ACTIVITY FREQUENCY DETAILS Note: Anderol 500 oil is a registered trademark of Anderol, Inc. and XL-700 oil is a registered trademark of Ingersoll-Rand Company. SCOTT SAFETY • • • Stages - Displays the PSI or BAR values for each stage. • • Alerts - Displays the gas type, live reading, and the unit of measure. Temperature - Displays the temperature value for the crankcase and the air in F/C.
32 CHAPTER 3: CONFIGURATION AND SETUP Using the Charge Station HMI The HMI has a charge screen that displays a color-coded quick view of the system and provides access various functions. Figure 13 HMI Charge Station Screen • SCBA Pressure - Displays the current pressure output to the SCBA cylinder. The cylinder gauge coincides with the graphic representation of cylinder 1 and 2. • Compressor Pressure - Displays the current pressure of the compressor.
Using the Charge Station HMI 33 Automatic Cascade fill may be performed using the HMI. Auto cascade allows cylinders to be filled from either the compressor or the storage tanks without any manual intervention, either mechanical or software. • Start Filling - Enables the SCBA fill in manual cascade mode. The following minimum requirements must be meet before fill is started: – The charge station door lock switch indicates the door is locked.
34 CHAPTER 3: CONFIGURATION AND SETUP Table 16 Alerts with Override Default Settings - Charge Station (continued) ITEM MEASUREM ENT RANGE ALARM TIME DELAY RANGE OVERR IDE COOL MANUAL MAX. DOWN OVERRIDE LIMIT CYCLE TIME ALARM ALARM ALARM DELAY WARNING SHUTDOWN STATES HORN ALARM Yes Up to 3 (1Hr) 20F 2Min Crank 10 to 100F case Min.
Using the Charge Station HMI 35 Table 16 Alerts with Override Default Settings - Charge Station (continued) ITEM MEASUREM ENT RANGE ALARM TIME DELAY RANGE TIME ALARM ALARM ALARM DELAY WARNING SHUTDOWN STATES HORN ALARM OVERR IDE COOL MANUAL MAX. DOWN OVERRIDE LIMIT CYCLE – Alerts without Overrides - These conditions display in the alert section of the HMI and each alert produces an associated audible alarm via the horn. However, no override is allowed. See Table 17. .
36 CHAPTER 3: CONFIGURATION AND SETUP Figure 14 Checklist - Screen Warning: All maintenance beyond the scope of this manual must be performed only by a Scott trained and certified service technician. Unauthorized maintenance or service without proper training can void the warranty, lead to permanent equipment damage, and/or serious personal injury. Warning: Be sure that the input electrical power supply is correct for the system to be powered.
Using the Charge Station HMI 37 Table 19 Pre-Operation Checklist - Charger Station ITEM ACTIVITY FREQUENCY DETAILS Air flow Check Before each operation Make sure there is nothing close to or on top of the compressor that could interfere with air flow. For proper operation, the minimum clearance established at installation on all sides and above the compressor must be maintained.
38 CHAPTER 3: CONFIGURATION AND SETUP Configuring the System This section covers configuring the system. The Supervisor access level allows additional functions beyond those allowed by the User. Only the Supervisor level access allows Configuration functions. The Supervisor access level allows normal operation of the Compressor and the Charge Station that is similar to that of the Operator access level. Supervisor level access allows the following: System • System - Used to configure the system.
Configuring the System 39 Figure 15 System Info Screen • Compressor - Displays various configurable parameters including: operating voltage, operating frequency, phase, compressor size, compressor type and storage tanks. • Charge Station - Displays various configurable parameters including: charge station type, and preset fill pressure. Both the alerts and pre-operation checklist icons shown on this various configuration screens are duplications of those already covered in other sections.
40 CHAPTER 3: CONFIGURATION AND SETUP Figure 16 Configuration - Preference Info Screen • Preference - Displays various configurable parameters including: language, units and time zone. All of the parameters on this screen are read only. • Settings Customer Information - Displays various configurable parameters including: name, location, contact into region and last service date. This section covers the various settings of the system. Used to configure the settings.
Configuring the System 41 Figure 17 Configuration - CO Calibration Screen • CO Calibration - Displays a sequence that performs the CO Calibration. Simply click on the start process button, the start calibration button, wait for the counter, next, wait for the counter and lastly finished. Ensure you adhere to the following warnings and cautions. Warning: Do not lubricate threads on the regulator, calibration gas cylinders nor the calibration port.
42 CHAPTER 3: CONFIGURATION AND SETUP Warning: Do not tighten. Over tightening may damage threads resulting in leakage. This leakage may expose user to carbon monoxide calibration gas resulting in serious injury or death. Warning: Follow calibration instructions completely. Failure to follow calibration instructions may result in incorrect calibration of device that may allow toxic gases to enter the breathing air resulting in serious injury or death. Charge Station See Figure 18.
Configuring the System 43 Figure 19 Charge Station - Pressure Calibration Screen • • • • • • • • • • • • • • SCOTT SAFETY Raw Min.
44 CHAPTER 3: CONFIGURATION AND SETUP Compressor See Figure 20. Figure 20 Compressor - General Setting Screen 087-0067 REV A • • • Compressor IP Address - Displays the IP Address of the Compressor. • Operating Frequency - Displays the selected Operating Frequency from the pull down menu. • • • Phase - Displays the selected Phase of the motor from the pull down menu. • • Save Button - Allows storage of the parameters listed above this button.
Configuring the System 45 • Toggle Purge - Allows changing its state. The individual state status of on or off is displayed below. • Individual State Status - Various state status are displayed based on user actions or the device’s parameter state.
46 CHAPTER 3: CONFIGURATION AND SETUP • • • Reset Selected Sensor Max Shutdown Alarm Value Update Shutdown Alarm Preferences See Figure 22. Figure 22 Preferences Screen • Preference - Displays various configurable parameters including: language, units and time zone. All of the parameters on this screen are read only.
Configuring the System 47 Customer See Figure 23. Figure 23 Customer Screen • Customer Information - Displays various configurable parameters including: name, location, contact into region and last service date. All of the parameters on this screen are read only.
48 CHAPTER 3: CONFIGURATION AND SETUP User Management See Figure 24. Figure 24 User Management Screen 087-0067 REV A • Users - Displays list of users and associated parameters. Includes: user name, pass code, RFID status, RFID serial number. • • • • • • • Roles - Displays roles. Add User - Allows entering new users. Remove User - Allows removal of users. Email ID - A unique qualifier for each user. User Credential - Shows the user’s first and last name.
Configuring the System Overrides 49 This section covers overrides. Allows you to override specific parameters. As long as you have permission. See Figure 25. Figure 25 Role Overrides Screen These parameters may be toggled and their associated minimum and maximum are displayed. • Temperature - Displays various configurable parameters including: maximum crankcase, minimum crankcase and air output. Allows changing its state. The individual state status of on or off.
50 CHAPTER 3: CONFIGURATION AND SETUP Figure 26 Override Settings Screen • 087-0067 REV A Exit Application - Allows exiting back to the logon screen.
Configuring the System 51 Figure 27 Override Status Screen SCOTT SAFETY 087-0067 REV A
52 CHAPTER 3: CONFIGURATION AND SETUP Using the RFID Read/Write Software This section covers the RFID software. The RFID Read/Write software is used with the applicable charge stations that provide the RFID functions. The software allows the reading and writing of data pertaining to the cylinders used in relation to the charge station. See Figure 28.
087-0067 Chapter 4 Rev A OPERATION Chapter Overview This chapter covers the following topics: • • • SCOTT SAFETY Compressor Overview Charge Station Overview Storage Overview 087-0067 REV A
54 CHAPTER 4: OPERATION Compressor Overview 087-0067 REV A In general, takes in ambient air and converts it into breathing air by way of various subsystems as outlined here: • Electrical subsystem - Electrical current (VAC) is used to power a motor inside the compressor that drives the compressor through a vee belt. • Filter and compression stages - The compressor, takes in ambient air that is filtered and then compressed in five stages.
Compressor Overview Compressor Interfaces 55 This section covers the compressor interfaces. The operation of the compressor varies based on the model. The Scott models use a HMI to operate the compressor. See “Configuration and Setup” on page 21. Other models do provide analog gauges, but do not provide a touch pad controller. Warning: When settings are changed, ensure those changes are communicated to all affected personnel. Depending on the configuration, the compressor may be controlled via the HMI.
56 CHAPTER 4: OPERATION guidelines or requirements of your organization. Exposure to high sound levels may cause temporary or permanent hearing loss in some individuals. Caution: Verify the correct compressor rotation before operation. Rotation should be counterclockwise when facing the compressor fan. See the arrows on the compressor belt guard. If the rotation is incorrect, do not use the power source until the phasing has been modified by a certified electrical technician.
Compressor Overview 57 the cool down cycle, the compressor stops. If the system is in the Automatic Mode, the compressor restarts to refill the storage when the system pressure drops about 6200psi below the desired maximum pressure. In contract, if the system is in Manual Mode, you must press Start on the HMI after the storage pressure drops about 6200psi from full to restart the compressor to refill the storage.
58 CHAPTER 4: OPERATION Charge Station Overview This section covers an overview of the charge station. We provide a full line of breathing air system components and related accessories for the safe production and storage of compressed breathing air. Configurations of breathing air systems will vary depending on selected options. Operators of these units must become familiar with their particular system configuration and refer to the proper operating instructions.
Charge Station Overview 59 For systems with an integral compressor, the operator can choose to turn Off the compressor after filling the storage and then fill the breathing air cylinders. The Auto Cascade system will provide the maximum number of fills before turning the compressor back On. Charge Station Interfaces This section describes the different charge station interfaces. The operation of the charge varies based on the model. The Scott models use a HMI to operate the charge station.
60 CHAPTER 4: OPERATION Table 20 Charge Model Interfaces MODEL FUNCTIONS DETAILS 8004440, Fully Automatic System with LCD 8004448, 8004442, 8004444, 8004452 See “8004440, 8004448, 8004442, 8004444, 8004452” on page 60. 8004445, Analog System without LCD, Automatic 8004447 Cascade/Bulk and Dual Pressure See “004445, 8004447” on page 61. See “8004450, 8004451” on page 62.
Charge Station Overview 61 004445, 8004447 This section covers the various interfaces for these models. See Figure 32 and Table 22. Figure 32 8004445, 804447 Interface Locations 6 7 8 1 3 2 4 5 Table 22 8004445, 8004447 Interfaces Details REFERENCE NUMBER SCOTT SAFETY ITEM 1 SCBA Fill Pressure Analog Gauge - Indicates the SCBA pressure. 2 Manual Air Flow On/Off Knob - Allows air pressure from the storage to the SCBA cylinder. 3 Pressure Regulator - Controls the pressure output to the SCBA.
62 CHAPTER 4: OPERATION 8004450, 8004451 This section covers the various interfaces for these models. See Figure 33 and Table 23. Figure 33 8004450, 8004451 Interface Locations 6 7 1 2 3 4 5 Table 23 8004450, 8004451 Interfaces Details REFERENCE NUMBER 087-0067 REV A ITEM 1 SCBA Fill Pressure Analog Gauge - Indicates the SCBA pressure. 2 Manual Air Flow On/Off Knob - Allows air pressure from the storage to the SCBA cylinder. 3 Pressure Regulator - Controls the pressure output to the SCBA.
Charge Station Overview Charging the SCBA Cylinders 63 This section cover charging the SCBA cylinders. Using the charge station turntable chamber, two SCBAs may be charged simultaneous while two more SCBAs are being mounted. Caution: Before starting, check the inspect the SCBA cylinders. See “Breathing Air Cylinder Inspection” on page 75. Warning: When charging more than one breathing air cylinder together, charge only cylinders that have the same pressure rating.
64 CHAPTER 4: OPERATION Model depending, either refer to the LCD or the control panel on the charge station. These instructions are based on a control panel interface. Figure 34 Cylinder Charging Controls 6 7 8 1 3 2 4 5 Table 24 Cylinder Charging Controls REFERENCE NUMBER ITEM 1 SCBA Fill Pressure Analog Gauge - Indicates the SCBA pressure. 2 Manual Air Flow On/Off Knob - Allows air pressure from the storage to the SCBA cylinder.
Charge Station Overview 65 Figure 35 Charging Chamber Unlocked 1 5 Close the Manual Air Flow On/Off Knob on the control panel by turning the valve fully clockwise. Warning: Never set the fill pressure higher than the maximum pressure rating for the breathing air cylinders to be filled. Filling breathing air cylinders beyond their maximum pressure rating may result in serious damage to the cylinder or cylinder valve. A damaged cylinder may rupture, and can cause serious personal injury or death.
66 CHAPTER 4: OPERATION Figure 36 Bleed Value and Charge Adapters Locations 2 1 2 7 Make sure all four of the cylinder charge adapters (item 2) are closed and secure (two on each side of the fill station door). Hand-tighten, turning the adapter counterclockwise. Do not use tools. 8 Close the charging chamber and lock with the operating handle (with the Yellow locking bars visible around the chamber door). 9 Open the Manual Air Flow On/Off Knob 1/8 to 1/2 turn counterclockwise.
Charge Station Overview Cylinders Mounting and Charging 67 This section covers mounting and charging the cylinders. 1 Close the Manual Air Flow On/Off Knob. Slowly open the bleed valve just enough to vent any residual pressure. When all air stops escaping, hand-tighten the bleed valve. Do not use tools to tighten. See Figure 37. Figure 37 Bleed Value and Charge Adapters Locations 2 1 2 Caution: Never use a wrench or other tool to tighten the bleed valves or cylinder adapters.
68 CHAPTER 4: OPERATION Figure 38 Rotating Camber Door Warning: Use extreme caution when rotating the chamber door. Catching fingers, hands, hair, articles of clothing, or other objects in the door may result in personal injury or damage to the fill station. 7 Close and lock the charging chamber door handle. The door is locked when the Yellow lock bars are visible around the door frame. 8 Open the Manual Air Flow On/Off Knob 1/8 to 1/2 turn counterclockwise to begin filling the cylinders.
Charge Station Overview 69 12 While the breathing air cylinders are being filled inside the charge chamber, mount the second set of cylinders on the rigid adapters on the outside of the charge chamber. Be sure to hand-tighten the bleed valve and to open the breathing air cylinder valve(s). 13 When the breathing air SCBA Cylinder Pressure Gauge reaches the pre-set charge pressure, open the chamber lock by operating the handle so that the Yellow lock bars are not showing.
70 CHAPTER 4: OPERATION Storage Overview The compressor may be configured to direct compressed and purified breathing air to an optional air storage unit. Storage units may meet peak demands for compressed air without requiring of a full time operation of a compressor. Stored air may be used to carry on operations if a compressor fails, loses power or when air is needed when a compressor is not available. All storage units are equipped with service values and safety relief gauges.
Storage Overview Storage Interfaces 71 This section covers the interfaces for storage. See Figure 39 and Table 25. Figure 39 Storage Interfaces Location 2 1 3 Table 25 Storage Interfaces Details REFERENCE NUMBER ITEM* 1 Manual Air Flow On/Off Knob - To control the air flow pressure. 2 Analog Pressure Gauge - Displays pressure in cylinder. 3 Automatic Relief Value - To control or limit the pressure. *Note: Not all models are equipped the same.
72 CHAPTER 4: OPERATION The Cascade configuration, depending on the model, includes individual gauges on the control panel or on the HMI, and control valves for monitoring and controlling the flow of compressed air in each cylinder. Each cylinder may be isolated, or “shut off” to prevent compressed air from entering or exiting the cylinder. To isolate a cascaded cylinder, simply turn the control valve clockwise to shut off the air flow.
087-0067 Chapter 5 Rev A MAINTENANCE Chapter Overview This chapter covers the following topics: • • • • SCOTT SAFETY Storage Cylinder Inspection Breathing Air Cylinder Inspection Maintaining the Compressor Troubleshooting the Compressor 087-0067 REV A
74 CHAPTER 5: MAINTENANCE Storage Cylinder Inspection This section covers storage cylinder inspection. Warning: Do not refill any cylinder that is damaged or not within the prescribed hydrostatic test date as determined by the appropriate US Department of Transportation (DOT) specification or the applicable DOT exemption or in accordance with the appropriate Transport Canada (TC) Permit of Equivalent Level of Safety. Damaged cylinders may suddenly leak or rupture if charged with compressed air.
Breathing Air Cylinder Inspection Breathing Air Cylinder Inspection 75 This section covers inspection of the breathing air cylinder. See “Warnings and Cautions – Working with Compressed Air” on page xix. Refer to current applicable publications on compressed gas cylinder inspection available from Compressed Gas Association Inc., 1725 Jefferson Davis Hwy., Suite 1004, Arlington, VA 22202, (703-412-0900) for a detailed explanation of cylinder inspection procedures.
76 CHAPTER 5: MAINTENANCE charred or missing, pressure gauge lens melted or elastomeric bumper distorted, and cylinders which show evidence of exposure to chemicals such as discoloration, cracks in the cylinder or the composite wrapping, peeling of the outer layers of the composite wrapping and/or bulging of the cylinder wall, shall be removed from service and emptied of compressed air. 3 Always check the pressure rating of the selected breathing air cylinder(s) to be filled.
Maintaining the Compressor Maintaining the Compressor 77 This section covers maintenance of the compressor. The HMI provides a Checklist of Pre-Operation items for the compressor. See “Using the Compressor HMI” on page 25. Table 27 lists recommended maintenance schedule by days/hours. Table 28 lists a number of user level maintenance items.
78 CHAPTER 5: MAINTENANCE Table 27 Recommended Maintenance Schedule - Users (continued) ITEM WEEKLY* Remove Air Intake Inspection 90 DAY 50 HOUR 200 HOURS OR ANNUALLY X** X** X** Storage Inspection/Drain and Recharge Run Compressor (60Mins), 2 Min Cool Down 500 HOURS OR ANNUALLY X** X X Wiring and Cables (Inspection) X**** Bleeder Value Service (Charge Station) AR Door Detent Lubrication (Change Station) AR Nipple Seal Replacement (Charge Station) AR X X X * Note: See manufacture
Maintaining the Compressor 79 Table 28 Recommended Maintenance Matrix - Users ITEM Draining the Condensate Container ACTIVITY/ SYMPTOM FREQUENCY DETAILS Compressor Operate Weekly Run the compressor for a period of not less than one hour allowing for at least four condensate drain cycles. This prohibits moisture build up in the unit and provides proper lubrication. Nuts, Screws, Fittings Inspect Weekly Inspect all nuts, screws, and fittings for tightness.
80 CHAPTER 5: MAINTENANCE For HMI equipped models, an Alert is generated when the container is 3/4 full and the device automatically shuts down when container is full. Figure 41 Condensate Container Location Replacing the Fuses This section covers replacing the fuses. 1 If the compressor electrical motor is inoperative, check the coil fuses (2) on the outside of the electrical control box. See Figure 42. Only use replacement fuses with the same size and rating as the fuse being replaced.
Maintaining the Compressor Resetting the Motor Saver 81 This section covers resetting the motor saver. The optional motor saver protects the compressor motor by monitoring the power line. When the power on the line exceeds a safe limit, the motor is disabled. To enable the motor, press the Motor Saver Reset button on the outside of the electrical control box. See Figure 43.
82 CHAPTER 5: MAINTENANCE Checking the Inlet Filter This section covers checking the inlet filter. The operator should check the inlet filter located on top of the compressor after prolonged use (approximately 100 hours of operation in normal conditions, or 50 hours if operating in dusty or dirty environments). See Figure 45. To change the filter: 1 Loosen the wing nuts to open the filter housing. 2 Remove the cover and inspect the element for excessive build up of dirt and particles.
Maintaining the Compressor Checking the Drive Belt 83 This section covers checking the drive belt. The compressor drive belt has automatic tensioning. When the compressor is not running, check the condition of the compressor belt. If the belt is frayed or damaged, do not use the compressor until the belt is replaced. It should be replaced as needed by Scott trained and certificated service technician. See Figure 47. Figure 47 Drive Belt Location Changing the Oil This section covers changing the oil.
84 CHAPTER 5: MAINTENANCE Figure 48 Oil Drain Location 3 2 1 087-0067 REV A SCOTT SAFETY
Troubleshooting the Compressor Troubleshooting the Compressor 85 Refer to Table 29 for troubleshooting assistance. Warning: If the device does not function properly, remove from service and mark for maintenance. Only use Scott Safety replacement parts. Table 29 Troubleshooting Matrix SYMPTOM SOLUTION Excessive stage 1 Faulty suction or pressure delivery value(s) 2 Pressure gauge not accurate. 3 Restriction in pipeline. 4 Air leakage in pipe system or from machine 5 Wear. 6 Loss of drive.
86 CHAPTER 5: MAINTENANCE Table 29 Troubleshooting Matrix (continued) SYMPTOM CAUSE Either: 1 Intel temperature Excessive stage higher than pressure recommended maximum. and 2 Insufficient Insufficient supply. pressure or volume. 3 Inlet or delivery values not closing properly. 4 Cylinder fins clogged or dirty. 5 Intercooler and aftercooler tubes dirty. 6 Belt drive slipping. 7 Air intake filter dirty. 8 Wrong rotation. 087-0067 REV A SOLUTION 1 Check that pipe works/values do not form a closed loop.
087-0067 Appendix A Rev A SPECIFICATIONS Appendix Overview This appendix covers the following topic: • SCOTT SAFETY Specifications 087-0067 REV A
88 APPENDIX A: SPECIFICATIONS Specifications Table 30 lists the specifications. Table 30 Specification SPECIFICATIONS Compressor Input Voltage Range 208VAC to 460VAC Input Frequency Range AC: 60Hz or 50Hz Fuse 1A, 600VAC HMI Screen - Wall Mount (Available on standalone models) 10.5” color Communications Wi-Fi for customer Wireless LAN 1 Ethernet RJ45 connector on the side for customer LAN CAT5E cable, up to 300Feet Max. for LAN 087-0067 REV A Horse Power 7.
Specifications 89 Table 30 Specification (continued) SPECIFICATIONS Charge Station Input Voltage Range 100VAC to 240VAC 110VDC to 250VDC Input Frequency Range AC: 60Hz or 50Hz Max. Input Current 12.24A HMI Screen 10.5” color Communications Wi-Fi for customer Wireless LAN 1 Ethernet RJ45 connector on the side for customer LAN CAT5E cable, up to 300Feet Max.
90 APPENDIX A: SPECIFICATIONS 087-0067 REV A SCOTT SAFETY
087-0067 Appendix B Rev A SUPPORT Appendix Overview This appendix covers the following topics: • • SCOTT SAFETY Technical Service Limited Warranty 087-0067 REV A
92 APPENDIX B: SUPPORT Technical Service Congratulations on your purchase of a Scott Safety product. It is designed to provide you with reliable trouble-free service. Contact us, if you have technical questions, need support, or if you need to return a product. When returning a product, contact Technical Support to obtain a Return Material Authorization (RMA) number prior to shipping for service repairs.
Technical Service 93 Germany Telephone: 0180 1111 136 Fax: 0180 111 135 E-Mail: scott.sales.ger@tycoint.com France Telephone: 08 21 23 02 38 Fax: 08 21 23 02 37 E-Mail: scott.sales.france@tycoint.com UAE Telephone: +971 (02) 445 2793 Fax: +971 (02) 445 2794 E-Mail: scott.sales.emirates@tycoint.com China China, Beijing, Technical Support Office Beijing branch, Shanghai Eagle Safety Equipment Co. Ltd. Suite 708, Scitech Tower, No.22 Jianguomenwai Avenue, Chaoyang District, Beijing, 100004, P.R.
94 APPENDIX B: SUPPORT Limited Warranty Scott Safety (SCOTT), warrants the Compressor, Charge Station and Storage (THE PRODUCTS) to be free from defects in workmanship and materials for a period of five (5) years from the date of original manufacture by SCOTT or 1000 hours whichever comes first. This warranty applies to all components of THE PRODUCTS, EXCEPT expendable components such as oil, air filters, oil filters.
087-0067 Rev A INDEX C H Categories Compressor System 3 Charge Station Major Parts Example 7 Models 6 Charge Station Screen HMI 32 Checklist Installation 13 Compressor Major Parts Example 4 Compressor Screen HMI 25 Compressor System Categories 3 Condensate Container Location 80 Contact Information Technical Support 92 High Pressure Button Location 81 HMI Charge Station Screen 32 Compressor Screen 25 Firmware Version 22 Login Screen 23 D Drive Belt Location 83 E Example Storage Unit 8 I Information G
96 INDEX O Oil Drain Location 84 P Parts RFID Read/Write Scanner 17 Purification Filter Location 82 R Related Product Documentation xiii Revision history, for this guide xiv RFID Read/Write Scanner 17 RFID Read/Write Scanner Parts 17 RFID Read/Write Software Screen 52 S Scanner RFID Read/Write 17 Screen RFID Read/Write Software 52 Storage Unit Example 8 Major Parts Example 9 T Technical Support Contact Information 92 Troubleshooting Matrix 85 W Warnings and Cautions Device Use and Care xix Working wi
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