Tank Farm Plant Operating Procedure 242-A Evaporator USQ # EV … · 2019. 1. 10. · 5.1 Glycol Cooling and Air Receiver R-E-1Valve Line-up 5.1.1 IF directed by Shift Manager, PERFORM

Operate 242-A Evaporator Compressed Air System

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Tank Farm Plant Operating Procedure 242-A Evaporator

USQ # EV-18-0421-S, Rev.1

CHANGE HISTORY ( LAST 5 REV-MODS )

Rev-Mod Release Date Justification: Summary of Changes

O-5 09/26/2018 Periodic review comment

resolution

Formatting changes/updates to comply with standard.

Updated Radiation and Contamination Control statement in 3.2.1.

Modified equipment identification tags in tables.

Updated HV-CP1-1 and HV-CP2-1 in checklist 1 to condensate

drains. Updated records section. Replaced figure 1 with new

updated version from TO-600-160. Replaced signature sheet with

one from standard.

O-4 03/15/2018

Operations Request - It was

noted during a procedure

walkdown by the SOE's that

HV-CW-25 was not inside the

AMU, but was located outside

the pump and cooling pad

The HV-CW-25 row was deleted from table "Valving Inside

AMU" (located in page 33 of TO-620-160 Checklist 1) and added

to table "Valving Outside on Pump and Cooling Pad" (located in

page 33 of TO-620-160 Checklist 1)

Struck out Step 4.2.1

O-3 01/30/2017 Operations Request

Removal of Sahara Air Dryer and Portable Air Compressor from

procedure. The following sections were removed to accommodate

this: 5.5, 5.6, 5.7, and 5.13. Removed figure 3 and 4.

O-2 07/18/2016 Record management request Update the records section.

O-1 03/31/2016 Operations request Page 52 Figure 3 changed "MCC1" to "MCC-1" to match field.

Table of Contents Page

1.0 PURPOSE AND SCOPE ................................................................................................................ 3

1.1 Purpose ................................................................................................................................ 3

1.2 Scope ................................................................................................................................... 3

2.0 INFORMATION............................................................................................................................. 3

2.1 Terms and Definitions......................................................................................................... 3

2.2 General Information ............................................................................................................ 3

3.0 PRECAUTIONS AND LIMITATIONS......................................................................................... 5

3.1 Personnel Safety.................................................................................................................. 5

3.2 Radiation and Contamination Control ................................................................................ 5

4.0 Special Tools, Equipment, and Supplies......................................................................................... 6

4.1 Performance Documents ..................................................................................................... 6

4.2 Field Preparation ................................................................................................................. 7

5.0 PROCEDURE ................................................................................................................................. 8


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5.1 Glycol Cooling and Air Receiver R-E-1Valve Line-up ..................................................... 8

5.2 Initial Start-Up or Re-Start after Prolonged Outage ........................................................... 9

5.3 Normal Compressor Start-Up ........................................................................................... 16

5.4 Shutdown Air Compressors/Glycol Cooling .................................................................... 21

5.5 CP-E-1/CP-E-2 Setup Maximum Pressure at Sigma V-7 Controller ............................... 22

5.6 Reset P1/P2 Lead/Lag Pressure Configuration ................................................................. 24

5.7 Reset and Synchronize P1/P2 Timers for CP-E-1 and CP-E-2 ......................................... 27

5.8 Air Compressors CP-E-1/CP-E-2 Clock Check/Synchronization .................................... 29

5.9 Activate/Enter the Password for CP-E-1/CP-E-2 ............................................................. 31

5.10 Records ............................................................................................................................. 32

Checklist 1 - Glycol Cooling System Valving - Startup ........................................................................... 33

Checklist 2 - Kaeser Compressor Valve Line-Up - Startup ...................................................................... 34

Checklist 3- Air Receiver R-E-1 Valving - Startup .................................................................................. 35

Checklist 4 - Air Receiver R-E-1 Re-pressurization Valving - Startup .................................................... 36

Figure 1 - Glycol/Water Compressor Cooler Valving .............................................................................. 37

Figure 2 - Process Air System Compressors and Air Receiver R-E-1 ..................................................... 38

Figure 3 - Adding Cooling Oil to Airend.................................................................................................. 39

Figure 4 - Sigma Control Display, Keys/Buttons and Indicators ............................................................. 40

Figure 5 - Sigma Control Main Menu Overview ...................................................................................... 42

Figure 6 - Configuration Menu Tree ......................................................................................................... 43

Signature Sheet 1 ...................................................................................................................................... 44

Attachment 1 – Alarm Messages for Machine Shutdown ........................................................................ 45

Attachment 2 – Warning Messages (Yellow Lights) ................................................................................ 49

Attachment 3 – Other Faults ..................................................................................................................... 53


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1.0 PURPOSE AND SCOPE

1.1 Purpose

This procedure provides instructions for the start-up, operation, and shutdown of the

242-A Compressed Air System.

1.2 Scope

This procedure applies to the 242-A Compressed Air System and its associated

instrumentation and controls.

2.0 INFORMATION

2.1 Terms and Definitions

AMU - Aqueous Make Up

SM/OE - Shift Manager/Operations Engineer.

2.2 General Information

2.2.1 Refer to Figure 4 for Control Panel, Function Key/Button menu.

2.2.2 The oil level indicator for Compressors CP-E-1 and CP-E-2 is always checked under load, and after running for approximately 20 minutes.

2.2.3 If the Maintenance Warning is flashing (see Figure 4, Item 15) pressing the

Information “ ” key/button will determine the event/cause.

2.2.4 To establish which unit (CP-E-1 or CP-E-2) is acting as the “Lead” compressor at any given time, the following conditions will be the

determining factors:

If “P1” is displayed in the lower left hand corner of Sigma Display, CP-E-1 is the lead and CP-E-2 is the lag compressor

If “P2” is displayed in the lower left hand corner of Sigma Display, CP-E-2 is the lead and CP-E-1 is the lag compressor.

2.2.5 After program information has been input using the SIGMA Control, always press the “Enter” key/button to save the information.

2.2.6 SIGMA display values can only be changed when the value is in the 3rd line

of display and is denoted by the symbol (see Section 5.9 for graphic).

Pressing the “Enter” key/button selects that value for editing.


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2.2 General Information (Cont.)

2.2.7 Editing the selected value(s) is performed by using the “Up” and/or “Down” keys. The “Esc” key can be used to exit the editing process at any time prior

to hitting “Enter”. Edited information will be saved by pressing the “Enter”

key when done. The “Esc” key is used to return to the Main Menu after the

editing process is complete.

2.2.8 If a compressor is stopped underload i.e., pressing E stop, loss of power, improper compresor shut down, etc. oil from the airend may be pushed up

into the air linlet filter and housing.

2.2.9 At Operations’ earliest opportuntity, the air inlet filter housing should be wiped down and filter inspected. If filter is damaged it should be replaced.

2.2.10 If power is lost on a compressor (disconnect opened or experienced loss of power) when power is returned the P1/P2 cycle timer resets. The compressor

will start up in the P2 mode and will continue to run in P2 mode until the

P1/P2 cycle timer sees the hour that has been established for compressors to

switch modes. At that hour the compressor will go to P1 mode and the timer

will reset to 168 hours.

2.2.11 Anytime a compressor(s) has been either de-energized (disconnect opened) or experience loss of power, when reenergized, both CP-E-1 and CP-E-2 will

need to be Reset and Synchronize per Section 5.7.

2.2.12 Section 5.7 must always be performed on both CP-E-1 and CP-E-2 at the same time to keep the compressor switching sequence cycle consistent.

2.2.13 If the LOAD/IDLE key on the compressor Sigma Control Display (refer to Figure 4) is pressed while the compressor is idling, the compressor will

remain in idle mode and will not load until the LOAD/IDLE key is pressed

again.


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3.0 PRECAUTIONS AND LIMITATIONS

3.1 Personnel Safety

WARNING - During compressor starts, rotating equipment may potentially cause

personnel injuries.

3.1.1 Exercise caution when around air compressors. Compressors are rotating equipment and may start up automatically at any time.

3.1.2 Working on or near air compressors may require hearing protection.

3.1.3 If a lock and tag is required during the performance of this procedure, comply with the DOE-0336, Hanford Site Lockout/Tagout Procedure.

3.1.4 Compliance with DOE–0359, Hanford Site Electrical Safety Program is required when working with electrical equipment.

3.2 Radiation and Contamination Control

3.2.1 Work in radiological areas will be performed using a Radiological Work Permit following review by Radiological Control per ALARA work planning

procedure TFC ESHQ RP_RWP C 03.

3.2.2 When work is performed in or when work will result in a high contamination, high radiation, or an airborne radioactivity area, an approved work package

must be developed which is reviewed by Radiological Control per ALARA

work planning procedure TFC-ESHQ-RP_RWP-C-03.

3.2.3 The opening of any system or component within a radiological area requires the presence of a Health Physics Technician to verify contamination control.


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4.0 SPECIAL TOOLS, EQUIPMENT, AND SUPPLIES

The following supplies may be needed at the work place:

Ladder

Bucket

SIGMA Fluid Cooling Oil

Kaeser supplied key to access panels

Other tools, equipment, and supplies as identified by Shift Manager/OE/FWS.

4.1 Performance Documents

The following documents may be needed to perform this procedure:

TF-OR-PWR-03, 242-A Evaporator Stationary Operating Engineer Rounds

TO-230-140, Operate 241-AW Instrument Air System

Procedure 7-SA-790.

The following Sigma Control and Service manuals are located in Shift Office:

SIGMA CONTROL – Quick-reference Operating Inst., Version 72.00 05/03

Service Manual - Screw Compressor ASD T Tri-Voltage 9_5721 06 USE

Service Manual SIGMA CONTROL Index: 7_7000_0-00 10 USE – BUB 80.XX.


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4.2 Field Preparation

4.2.1 REPORT all deviations or discrepancies immediately to the Shift Manager.

4.2.2 REQUEST Shift Manager to identify required equipment and desired configuration for the following:

Required

()

Equipment Description Desired Configuration

(ON/OFF)

Initial*

CP-E-1 Compressor

CP-E-2 Compressor

CP-E-1 Glycol System

CP-E-2 Glycol System

* N/A if not required.

4.2.3 REQUEST Shift Manager to identify which Sections, (5.1 through 5.9) will be worked.

Identified Section(s)

/ /

Signature Print (First & Last) Date

Shift Manager /OE


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5.0 PROCEDURE

NOTE - See Step 4.2.3 for Sections to be worked. Those Sections identified in Step 4.2.3 must

be worked sequentially unless otherwise granted flexibility by means of notes or

specific work instructions found in work steps.

5.1 Glycol Cooling and Air Receiver R-E-1Valve Line-up

5.1.1 IF directed by Shift Manager, PERFORM glycol cooling system valving per Checklist 1.

5.1.2 CHECK surge tank TK-E-105 to ensure coolant level is approximately one-half full in sight glass.

5.1.2.1 IF coolant is low, ADD coolant per work package and manufacturer’s recommendations.

5.1.3 IF directed by Shift Manager, PERFORM valving for Kaeser compressor(s) per Checklist 2.

5.1.4 IF directed by Shift Manager, PERFORM Air Receiver valving per Checklist 3.


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5.2 Initial Start-Up or Re-Start after Prolonged Outage

Prepare Compressor for Initial Startup

5.2.1 IF this is not the initial Start-Up, or Re-Start after a prolonged outage, (> 3 months) GO TO Section 5.3.

5.2.2 IF this is the initial start-up or re-start after a prolonged outage for CP-E-1, (> 3 months), CONFIRM the following:

CP-E-1 DRY COOLER DISCONNECTS

LOCATION EQUIPMENT I.D. NUMBER POSITION CHECK

Outside by glycol chiller unit DC3-DS-1 OFF (Open)

CP-E-1 COMPRESSOR DISCONNECTS

Compressor No. 1 CPE1-DS-1 OFF (Open)

CP-E-1 COMPRESSOR BREAKERS

MCC-2, Comp. A7 Compressor CP-E-1 OFF (Open)

5.2.3 IF this is the initial start-up or re-start after a prolonged outage for CP-E-2, (> 3 months), CONFIRM the following:





Compressor No.2 CPE2-DS-1 OFF (Open)


MCC-2, Comp. A8 Compressor CP-E-2 OFF (Open)

5.2.4 NOTIFY Maintenance (for each compressor being started) to add SIGMA Fluid cooling oil to the air end inlet valve filling port per procedure 5-SA-789

242-A Kaeser Air Compressor Annual Maintenance.

5.2.5 IF open, CLOSE AND LATCH all access doors on Compressor(s).


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5.2 Initial Start-Up or Re-Start after Prolonged Outage (Cont.)

NOTE - The Emergency Stop push button (red) is located below the control panel of

the air compressors. If the Emergency Stop push button was used to stop the

compressor while under load, oil from the airend may have been pushed up

into the air inlet filter.

5.2.6 CHECK (for each compressor being started) that the “Emergency Stop” push button(s) are not latched in the “IN” position for each compressor.

5.2.6.1 IF “Emergency Stop” push button(s) is/are latched-in the “IN” position, NOTIFY Shift Manager AND

IF directed, LIGHTLY TWIST the “Emergency Stop” push

button(s) in counter-clockwise direction to unlatch.

5.2.7 IF identified in Step 4.2.2 to run CP-E-1 compressor without the glycol chiller unit, PERFORM lineup as follows:





MCC-2, Comp. A7 Compressor CP-E-1 ON (Closed)


Compressor No. 1 CPE1-DS-1 ON (Closed)

5.2.8 IF identified in Step 4.2.2 to run CP-E-2 compressor without the glycol chiller unit, PERFORM lineup as follows:







Compressor No.2 CPE2-DS-1 ON (Closed)


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5.2.9 IF identified in Step 4.2.2 to run CP-E-1 compressor with glycol chiller unit, PERFORM the following:







Outside by glycol chiller unit DC3-DS-1 ON (Closed)

Initial Startup or Restart of Air Compressor(s)









NOTE - When the disconnect switches and breakers are closed, the compressors

automatically performs a self-test before the compressor(s) may be started.

- Refer to Figure 4 for Control Panel, Function Key/button menu.

5.2.11 ALLOW the controller to carry out the self-test, THEN

CHECK the green LED “Controller Power” is illuminated.

5.2.12 IF compressor is in Alarm, NOTIFY Shift Manager of Alarm(s) AND

CLEAR the Alarm(s) by pressing the “Acknowledge/Reset” key/button.

5.2.12.1 IF the Alarm does not clear, NOTIFY Shift Manager AND

REFER to Attachment 1 through Attachment 3 as applicable to

clear the alarm(s).


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5.2.13 IF Maintenance Warning is Flashing/Lit NOTIFY Shift Manager AND

PERFORM the following:

5.2.13.1 PRESS the Information “ ” key/button to determine the event/cause.

NOTE - It is common for Condensate chamber to fill due to compressor

cooling after being shut off. This may leave the condensate

chamber full and between blow-down cycles resulting in a warning

on next start-up.

5.2.13.2 IF the event/cause is not condensate drain, NOTIFY Shift Manager/OE for resolution.

NOTE - The Condensate Drain Units are located inside the compressor

enclosure.

5.2.13.3 IF the cause is displayed as “Condensate drain” PRESS AND HOLD “Test” Button for > 2 seconds on applicable condensate

drain unit (flashing red alarm LED on unit) to force drain blow-

down.

5.2.13.4 IF the Condensate Drain unit blow-down was successful, (flashing red alarm LED on condensate Drain unit goes off),

PERFORM one of the following as applicable:

a. IF Maintenance Warning light does not clear, NOTIFY Shift Manager for resolution.

OR

IF Maintenance Warning light clears, GO TO Step 5.2.14.

5.2.13.5 IF the Condensate Drain unit blow-down was not successful; REPEAT the blow-down after the compressor has been started

and is under load at Step 5.2.15.9.

5.2.13.6 IF Maintenance Warning is still flashing, PRESS “Acknowledge/Reset” key/button AND

CONFIRM Maintenance Warning stops flashing and goes solid

yellow.


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5.2.14 CHECK displayed time and date on CP-E-1 and CP-E-2 are correct AND

IF not, REQUEST maintenance to reset per Procedure 7-SA-790.

5.2.15 PERFORM the following on compressor CP-E-1 and/or CP-E-2:

5.2.15.1 PRESS the “LOAD/IDLE” toggle key/button AND

CONFIRM the green LED “IDLE” is illuminated.

5.2.15.2 IF the compressor shows alarm/warning, NOTIFY Shift Manager.

WARNING

During compressor starts, rotating equipment may potentially

cause personnel injuries.

5.2.15.3 INFORM individuals in the area to stand clear for compressor start.

5.2.15.4 AFTER green LED “IDLE” is illuminated, PRESS “ON” key/button.

5.2.15.5 CONFIRM the following:

“Machine ON” green LED illuminates

The compressor(s) runs at idle.


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NOTE - If the compressor(s) are being reenergized (disconnect closed) after

being de-energized (disconnect open) the compressor(s) will start

up in “P2” mode.

- Allowing the compressor to idle for 1 minute ensures cooling oil

is distributed throughout the machine.

- The compressor may not go to “Load” if system air pressure is

above low setpoint of compressor. Use the following information

to evaluate the system pressure.

If “P1” is displayed CP-E-1 is the lead and CP-E-2 is the lag compressor


Lead compressor has a low setpoint of 105 psi and a high set point of 120 psi

Lag compressor has a low setpoint of 100 psi and a high set point of 115 psi.

5.2.15.6 AFTER allowing the compressor to idle for a minimum of one minute, PRESS the “LOAD IDLE” key.

5.2.15.7 CONFIRM the compressor switches to “LOAD” and delivers compressed air.

OR

IF the compressor does not go to load immediately, CHECK the

system pressure on the 1st line of the “Sigma Control Display”,

and the “P1” and “P2” Operation mode.

5.2.15.8 IF the system pressure is below the low setpoint for the compressor in the current operating mode and unit does not start,

NOTIFY Shift Manager/OE.

5.2.15.9 IF the Condensate drain unit blow-down was not successful in Step 5.2.13.5, PRESS AND HOLD “Test Button” for > 2

seconds on applicable condensate drain unit to force drain

blow-down.

a. IF the Maintenance Warning does not clear, NOTIFY Shift Manager/OE for resolution.


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NOTE - The oil level indicator for Compressors CP-E-1 and CP-E-2 is

always checked under load, and after a warm-up runtime of

approximately 20 minutes.

5.2.15.10 ALLOW the compressor(s) to run up to approximately 20 minutes to come up to running temperature.

5.2.15.11 CHECK the oil level indicator (mounted on the oil separator tank) reads between Low (Red) and High (orange) level AND

IF not, NOTIFY Shift Manager for resolution.

5.2.16 REPEAT Steps 5.2.11 through 5.2.15.11 for each compressor identified in Step 4.2.2.

5.2.17 RESET AND SYNCHRONIZE P1/P2 Timers for CP-E-1 and CP-E-2 per Section 5.7.

5.2.18 IF the glycol chiller unit is running by direction of Shift Manager/OE, PERFORM the following:

5.2.18.1 CHECK that coolant is flowing through sight glass on running compressor.

Compressor Sight Glass

CP-E-1 FG-CW-1

CP-E-2 FG-CW-2

5.2.18.2 IF coolant is not flowing, NOTIFY Shift Manager/OE.

5.2.19 ENSURE daily power operator rounds TF-OR-PWR-03 are performed to establish baseline.

5.2.20 MONITOR the compressor(s) for the first few hours of operation to ensure that it is operating correctly.


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5.3 Normal Compressor Start-Up

NOTE - The Emergency Stop push button (red) is located below the control panel of

the air compressors. If the Emergency Stop push button was used to stop the

compressor while under load, oil from the air end may have been pushed up

into the air inlet filter

5.3.1 CHECK that the “Emergency Stop” push buttons are not latched-in the “IN” position for each compressor.

5.3.1.1 IF “Emergency Stop” push button(s) is/are latched in the “IN” position, NOTIFY Shift Manager AND

IF directed, LIGHTLY TWIST the “Emergency Stop” push

button(s) in counter-clockwise direction to unlatch.

5.3.2 IF identified in step 4.2.2 to run CP-E-1 compressor without the glycol chiller unit, PERFORM lineup as follows:








5.3.3 IF identified in step 4.2.2 to run CP-E-2 compressor without the glycol chiller unit, PERFORM lineup as follows:









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5.3 Normal Compressor Start-Up (Cont.)

















NOTE - The compressor(s) will carry out a self-test prior to the green light coming on.

5.3.6 PERFORM Steps 5.3.7 through 5.3.16 for each compressor identified in Step 4.2.2.

5.3.7 ALLOW the controller to carry out the self-test, THEN

CHECK the green LED “Controller Power” is illuminated.

5.3.8 IF compressor is in Alarm, NOTIFY Shift Manager of Alarm(s) AND

CLEAR the Alarm(s) by pressing the “Acknowledge/Reset” key/button.

5.3.8.1 IF the Alarm does not clear, NOTIFY Shift Manager AND

REFER to Attachment 1 through Attachment 3 as applicable to

clear the alarm(s).


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5.3.9 IF Maintenance Warning is Flashing/Lit, NOTIFY Shift Manager AND

PERFORM the following:

5.3.9.1 PRESS the Information “ ” key/button to determine the event/cause.

NOTE - It is common for Condensate chamber to fill due to compressor

cooling after being shut off. This may leave the condensate

chamber full and between blow-down cycles resulting in a warning

on next start-up.

5.3.9.2 IF the event/cause is not condensate drain, NOTIFY Shift Manager/OE for resolution.

NOTE- The condenser Drain Units are located inside the compressor

enclosure.

5.3.9.3 IF the cause is displayed as “Condensate drain” PRESS AND HOLD “Test” Button for > 2 seconds on applicable condensate

drain unit (flashing red alarm LED on condensate drain unit) to

force drain blow-down.

5.3.9.4 IF the Condensate Drain unit blow-down was successful, (flashing red alarm LED on condensate drain unit goes off),

PERFORM one of the following as applicable:

a. IF Maintenance Warning light does not clear, NOTIFY Shift Manager for resolution.

OR

IF Maintenance Warning light clears, GO TO Step 5.3.10.

5.3.9.5 IF the Condenser Drain unit blow-down was not successful, REPEAT this action after the compressor has been under load at

Step 5.3.13.1.

5.3.9.6 IF Maintenance Warning is still flashing, PRESS “Acknowledge/Reset” key/button AND

CONFIRM Maintenance Warning stops flashing and goes solid

yellow.


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WARNING

During compressor starts, rotating equipment may potentially cause

personnel injuries.

5.3.10 INFORM individuals in the area to stand clear for compressor start.

5.3.11 PRESS the “ON” key/button (Refer to Figure 4 as necessary).

5.3.12 CONFIRM the “Machine ON” green LED illuminates.

5.3.12.1 IF the compressor shows alarm/warning, NOTIFY Shift Manager.

NOTE - If the compressor(s) is being started form either being de-energized (disconnect

open) or loss of power the compressor(s) will start up in “P2” mode.

- The compressor may not go to load if system air pressure is within normal

range. Use the following information to evaluate the system pressure.



Lead compressor has a low setpoint of 105 psi and a high set point of 120 psi

Lag compressor has a low setpoint of 100 psi and a high set point of 115 psi.

5.3.12.2 CONFIRM the compressor switches to “LOAD” and delivers compressed air

OR

IF the compressor does not go to load immediately, CHECK the

system pressure on the 1st line of the “Sigma Control Display”

and the “P1” and “P2” Operation mode.

5.3.12.3 IF the system pressure is below the low setpoint for the compressor in the current operating mode and unit does not start,

NOTIFY Shift Manager/OE.


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5.3.13 ALLOW Compressor(s) to charge system, THEN

CHECK air pressure is 100 to 120 psi as read from 1st line of Sigma Control

display.

5.3.13.1 IF the Condenser Drain unit blow-down was not successful in Step 5.3.9.5, PRESS AND HOLD the “Test Button” for > 2

seconds on applicable condensate drain unit to force drain blow-

down.

a. IF the Maintenance Warning does not clear, NOTIFY Shift Manager/OE for resolution, otherwise continue.

5.3.13.2 ALLOW the compressor(s) to run approximately 20 minutes to come-up to normal operating temperature.

5.3.13.3 CHECK the oil level indicator (mounted on the oil separator tank) reads between Low and High level AND

IF not, NOTIFY Shift Manager for resolution.

5.3.14 IF the glycol chiller unit is running by direction of Shift Manager/OE, PERFORM the following:

5.3.14.1 CHECK that coolant is flowing through sight glass on running compressor.

Compressor Sight Glass

CP-E-1 FG-CW-1

CP-E-2 FG-CW-2

5.3.14.2 IF coolant is not flowing, NOTIFY Shift Manager/OE.

5.3.15 REPEAT Steps 5.3.7 through 5.3.14.2 for each compressor identified in Steps 4.2.2.

5.3.16 IF the compressor(s) being started has been either de-energized (disconnect opened) during shutdown or was shut-down due to a loss of power,

RESET AND SYNCHRONIZE P1/P2 Timers for CP-E-1 and CP-E-2 per

Section 5.7.

5.3.17 ENSURE daily power operator rounds TF-OR-PWR-03 are performed to establish baseline.

5.3.18 MONITOR the compressor(s) for the first few hours of operation to ensure that it is operating correctly.


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5.4 Shutdown Air Compressors/Glycol Cooling

NOTE - Refer to Figure 4 for this Section.

5.4.1 PRESS the “LOAD IDLE” key/button.

5.4.2 CONFIRM machine switches to “IDLE” and IDLE LED flashes.

5.4.3 IF the compressor does not shift to “IDLE”, NOTIFY Shift Manager.

5.4.4 ALLOW the compressor to idle for at least five (5) minutes, PRESS the “OFF” key/button AND

CONFIRM the following:

“ON” LED extinguishes

Compressor(s) shuts down.


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5.5 CP-E-1/CP-E-2 Setup Maximum Pressure at Sigma V-7 Controller

NOTE - This Section will only be used if one of the compressors has failed and if

directed by the Shift Manager/OE.

- This Section is used to set the running compressor’s pressure settings to 120 psi with a System Differential (SD) of -15 psi with no lead/lag

relationship with the other compressor.

5.5.1 AT the direction of the Shift Manager/OE, PERFORM the following steps 5.5.2 through 5.5.15 on either CP-E-1 or CP-E-2.

5.5.2 ENTER level 4 Password by referring to Section 5.9 as applicable.

NOTE - SIGMA display values can only be changed when the value is in the 3rd line of

display and is denoted by the symbol (refer to Section 5.9 for graphic).


- Editing the selected value(s) is performed by using the “Up” and/or “Down” keys. The “Esc” key can be used to exit the editing process at any time prior




5.5.3 PRESS the “Up” key/button until “CONFIGURATION” appears in third (3rd) line of display AND

PRESS the “Enter” key/button.

5.5.4 IF “PRESS SETTINGS” is not visible, PRESS the “Down” key/button until “PRESS SETTINGS” appears AND

PRESS “Enter” key/button.

5.5.5 PRESS “Down” key/button until “LOAD CONTROL” appears AND


5.5.6 SCROLL past “LOCAL MODE” to “P1/P2 cycle” AND


5.5.7 SET to P1 using the down keys/button AND

CONFIRM by pressing “Enter”.


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5.5 CP-E-1/CP-E-2 Setup Maximum Pressure at Sigma V-7 Controller

(Cont.)

5.5.8 SCROLL down to “SETTINGS” AND

CONTINUE down to one line past “P1/P2 cycle”.

5.5.9 SET the number of hours for P1 and P2 to 168 hours by placing these values in the 3rd line and using the up/down keys/buttons (normal value is 168 hours

for plant operations).

5.5.10 SCROLL down to “START” AND

SET to “START P1” (confirm by pressing “enter” key/button).

5.5.11 SCROLL down one line AND

SET “Start cycle time” for CP-E-1 to approximately 30 minutes in the future

(will start this time today).

5.5.12 SCROLL back up to “LOCAL MODE” AND GO TO P1.

5.5.13 CHANGE “P1” to “P1/P2 cycle”.

5.5.13.1 PRESS “Enter” key/button THEN

PRESS “esc”.

5.5.14 SCROLL up to “COMPRESSOR” AND


5.5.14.1 SET P1 SP (setpoint) to 120 psi.

5.5.14.2 ENSURE SD is -15 psi.



5.5.15 PRESS “esc” repeatedly to return to Main Menu [top level].

5.5.16 NOTIFY Shift Manager/OE that air compressor has been programmed at maximum facility pressure for Operating mode.


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5.6 Reset P1/P2 Lead/Lag Pressure Configuration

Reset CP-E-1 Pressure

5.6.1 IF CP-E-1 does not need its P1/P2 pressure settings to be reset to lead/lag configuration, GO TO Step 5.6.14.

5.6.2 ENTER level 4 Password by referring Section 5.9 as applicable.














5.6.6 SCROLL past “LOCAL MODE” to “P1/P2 cycle”, PRESS “Enter” key/button.

5.6.7 SET to P1 using the up/down keys/buttons AND

CONFIRM by pressing “enter”.



5.6.9 ENSURE the number of hours for P1 and P2 to 168 hours (normal value is 168 hours for plant operations).


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5.6 Reset P1/P2 Lead/Lag Pressure Configuration (Cont.)

Reset CP-E-1 Pressure (Cont.)

5.6.10 SCROLL back up to “LOCAL MODE” AND

CHANGE “P1” to “P1/P2 cycle”.


PRESS “esc”.








5.6.13 GO TO Section 5.7.

Reset CP-E-2 Pressure

5.6.14 ENTER level 4 Password by referring to Section 5.9 as applicable.







5.6.18 SCROLL past “LOCAL MODE” to “P1/P2” cycle, PRESS “Enter” key/button.


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5.6 Reset P1/P2 Lead/Lag Pressure Configuration (Cont.)

Reset CP-E-2 Pressure (Cont.)

5.6.19 SET to P1 using the down keys/buttons AND

CONFIRM by pressing “enter”.

5.6.20 SCROLL down to “SETTINGS”, THEN


5.6.21 ENSURE the number of hours for P1 and P2 is 168 hours (normal value is 168 hours for plant operations).

5.6.22 SCROLL back up to “LOCAL MODE” AND

CHANGE “P1” to “P1/P2” cycle.


PRESS “esc”.








5.6.25 PERFORM Section 5.7 (to re-establish the lead/lag function of air compressors CE-P-1 and CE-P-2).


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5.7 Reset and Synchronize P1/P2 Timers for CP-E-1 and CP-E-2

5.7.1 DO NOT START this section if all work cannot be performed prior to 12:00 pm.

5.7.1.1 IF work on both compressors cannot be completed prior to 12:00 pm, WAIT until after 12:00 pm to start work.

5.7.2 PERFORM Steps 5.7.2 through 5.7.14 on CP-E-1 and CP-E-2 concurrently to set and synchronized time to current hour and minutes.

5.7.3 IF necessary, ENTER the level 4 Password by referring to Section 5.9.














5.7.7 SCROLL past “LOCAL MODE” to “P1/P2” cycle, PRESS “Enter” key/button.

5.7.8 SET to P1 using the up/down keys/buttons AND

CONFIRM by pressing “Enter”.


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5.7 Reset and Synchronize P1/P2 Timers for CP-E-1 and CP-E-2 (Cont.)


CONTINUE down to “START”.

5.7.10 SET to “START P1”.

5.7.11 SCROLL down one line AND

SET the “start cycle time” to 12:00 pm.

5.7.12 SCROLL back up to “Local Mode” AND

CHANGE “P1” to “P1/P2 Cycle”.

5.7.12.1 PRESS “Enter” key/button, THEN

PRESS “esc”.

5.7.13 RECORD the synchronized time in the “As-Left” column on each compressor’s Data Sheet.

5.7.14 PRESS “Esc” repeatedly to return to Main Menu [top level].


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5.8 Air Compressors CP-E-1/CP-E-2 Clock Check/Synchronization

NOTE - During Clock Check/Synchronization, the units must be powered up, but

should not be at Idle or under Load while synchronizing the two units.

- Section 5.8 may be performed independently as plant conditions dictate.

5.8.1 IF either unit is running; DETERMINE if unit is at “Idle” or if unit is under “Load”.

5.8.1.1 IF the unit is at “Idle”, PRESS the “OFF” key.

5.8.1.2 IF the unit is under “Load”, PRESS the “Load/Idle” key AND

AFTER unit switches to “Idle” PRESS the “OFF” key.

5.8.2 ENSURE the following valves from system air are positioned as indicated:

Valve # Position Check

HV-CPE1-5 CLOSED

HV-CPE2-5 CLOSED

Checking/Setting Date

5.8.3 CHECK the Date on both CP-E-1/CP-E-2 display.

5.8.4 IF the Date(s) are correct, GO TO Step 5.8.6.

5.8.5 IF the Date(s) are not correct, SET the Date(s) by performing Steps 5.8.5.1 through 5.8.5.8 on CP-E-1 and/or CP-E-2 as applicable.

5.8.5.1 ENTER the password by referring to Section 5.9.

5.8.5.2 FROM the Main Menu, SCROLL up to “CONFIGURATION,” AND

PRESS “Enter” key (refer to Figure 4 through Figure 6 as

necessary).

5.8.5.3 PRESS the “Down” key to “GENERAL” AND

PRESS “Enter” key.

5.8.5.4 PRESS the “Down” key repeatedly until the Date is displayed in the 3rd line of the display.

5.8.5.5 PRESS the “Enter” key and the cursor appears under the first numeral of the Date.


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5.8 Air Compressors CP-E-1/CP-E-2 Clock Check/Synchronization (Cont.)

Checking/Setting Date (Cont.)

5.8.5.6 CHANGE the Date with the “Down” or “Up” key AND

SAVE the Date with the “Enter” key.

5.8.5.7 REPEAT for month and year as applicable.

5.8.5.8 PRESS the “Escape” key repeatedly to return to Main Menu.

Checking/Setting Time

5.8.6 PERFORM Steps 5.8.7 through 5.8.9 on CP-E-1 and CP-E-2 concurrently to obtain synchronized time and to prevent display(s) from timing out.

5.8.7 FROM the Main Menu, SCROLL up to “CONFIGURATION” AND

PRESS “Enter” key (refer to Figure 4 through Figure 6 as necessary).

5.8.8 PRESS the “Down” key to “GENERAL” and PRESS “Enter” key.

5.8.9 PRESS the “Down” key until the Time is displayed in the 3rd line of the display.

5.8.10 IF the As-Found times of both units are synchronized to within one (1) minute, EXIT this Section.

5.8.11 IF the units are not synchronized, ENTER the level 4 password by referring to Section 5.9.

5.8.12 DETERMINE the following:

Which clock (CP-E-1 or CP-E-2) is closest to the actual time

Is this time accurate to within 5 minutes of actual time?

5.8.13 IF not within 5 minutes of actual time, SET one of the clocks to actual time.

5.8.14 SYNCHRONIZE the two clocks to 1 minute per Data Sheet by using the “Up” and “Down” keys to change the Time and the “Enter” key to save the

hour/minutes as required.

5.8.15 PRESS “Esc” repeatedly to return to Main Menu [top level].


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5.9 Activate/Enter the Password for CP-E-1/CP-E-2

NOTE - The following passwords have been entered in the controller at the factory:

Password for Level Zero (0): 00000

Password for Level Four (4): 12EXP.

5.9.1 AT the Main Menu PRESS the “UP” key/button repeatedly UNTIL “PASSWORD” appears in the third (3rd) line of display THEN


5.9.2 PRESS the “Enter” key/button and the cursor appears under the first character of the password (e.g. XXXXX).

5.9.3 PRESS the “Down” key/button or the “Up” key/button repeatedly until the required character appears.

5.9.4 PRESS the “Enter” key/button and the cursor jumps to the next character of the password.

NOTE - After entering the last character the activated “password level” is displayed (in

this case Level Four (4).

5.9.5 SET the remaining characters of the password until password is complete as shown below.

5.9.6 PRESS the “Escape” key/button repeatedly to return to Main Menu [top level].


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5.10 Records

5.10.1 PERFORM the following for records identified within this procedure.

5.10.1.1 RECORD the number of times the record was generated in applicable column

OR

PLACE a check mark () in the N/A column.

5.10.1.2 SUBMIT the package for verification of completed records.

Records Submittal Checklist

Number

of times

completed

N/A

()

4.2 Field Preparation Step 4.2.2

Step 4.2.3

Checklists Checklist 1 - Glycol Cooling System Valving - Startup

Checklist 2 - Kaeser Compressor Valve Line-Up - Startup

Checklist 3- Air Receiver R-E-1 Valving - Startup

Checklist 4 - Air Receiver R-E-1 Re-pressurization Valving - Startup

Signature Sheets

Signature Sheet 1

FWS/OE/Shift Manager SEND the completed records to the Central Shift Office for records

retention.

/ /


FWS/OE/Shift Manager

The record custodian identified in the company-level Records Inventory and Disposition

Schedule (RIDS) is responsible for record retention in accordance with TFC-BSM-

IRM_DC-C-02.


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Checklist 1 - Glycol Cooling System Valving - Startup

Valve

Number Description Valve Position Operator Initials

Valving Outside on Pump and Cooling Pad

HV-CW-1 P-3 Supply Isolation Valve OPEN

HV-CW-2 P-4 Supply Isolation Valve OPEN

HV-CW-3 P-3/P-4 Supply Line Isolation Valve OPEN

HV-CW-4 P-3/P-4 Supply Line Isolation Valve OPEN

HV-CW-5 DC-3 Supply Isolation Valve OPEN

HV-CW-6 DC-3 Return Isolation Valve OPEN

HV-CW-7 DC-4 Supply Isolation Valve OPEN

HV-CW-8 DC-4 Return Isolation Valve OPEN

HV-CW-13 PI-CW-1 and Glycol Fill Port Isolation Valve OPEN

HV-CW-14 Glycol Fill Port CLOSED

HV-CW-20 P-3/P-4 Return Line Isolation Valve OPEN

HV-CW-21 P-3 Return Line Isolation Valve OPEN

HV-CW-22 P-4 Return Line Isolation Valve OPEN

HV-CW-25 P-3/P-4 Inlet Drain Valve CLOSED

Valving Inside AMU

HV-CW-9 CP-E-1 Return Isolation Valve OPEN

HV-CW-10 CP-E-2 Return Isolation Valve OPEN

HV-CW-11 CP-E-1 Supply Isolation Valve OPEN

HV-CW-12 CP-E-2 Supply Isolation Valve OPEN

HV-CW-17 CP-E-1/2 Supply Isolation Valve OPEN

HV-CW-18 TK-E-105 Sight Glass Isolation Valve OPEN

HV-CW-19 TK-E-105 Sight Glass Isolation Valve OPEN

HV-CW-23 CP-E-1 Supply Drain Valve CLOSED

HV-CW-24 CP-E-2 Supply Drain Valve CLOSED

HV-CP1-1 CP-E-1 Condensate Drain Valve OPEN

HV-CP2-1 CP-E-2 Condensate Drain Valve OPEN

* Green seal on valve indicates CLOSED; Red seal indicates OPEN.

Shift Manager Review: / / ________________



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Checklist 2 - Kaeser Compressor Valve Line-Up - Startup

Valve Number Description Valve Position Operator

Initials

CPE1/CPE2 Valves

HV-CPE1-7 CPE1 Outlet Air Vent to Atmosphere CLOSED

HV-CPE1-5 Outlet Air Isolation Valve (to Air Receiver) OPEN

HV-CPE2-7 CPE2 Outlet Air Vent to Atmosphere CLOSED

HV-CPE2-5 Outlet Air Isolation Valve (to Air Receiver) OPEN





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Checklist 3- Air Receiver R-E-1 Valving - Startup

Valve Number Description Valve Position Operator Initials

HV-RE1-4 R-E-1 strainer CLOSED

HV-RE1-12 Hose Connection supply valve CLOSED

HV-RE1-10 Process air connect (capped) CLOSED*

HV-IA-RE1-2 PCV-RE1-1 strainer CLOSED

HV-IA-RE1-3 Hose connection supply valve CLOSED

HV-IA-RE1-4 PCV-RE1-1 bypass CLOSED

HV-RE1-9 Hose connection isolation valve OPEN*

HV-RE1-1 Supply air to HV-CPE1-2/CPE2-2 OPEN*

HV-RE1-3 R-E-1 drain trap bypass CLOSED

HV-RE1-2 R-E-1 drain trap inlet OPEN

HV-RE1-5 R-E-1 drain trap outlet OPEN

HV-RE1-6 FI-RE1-1 inlet OPEN*

HV-RE1-7 FI-RE1-1 outlet OPEN*

HV-RE1-13 FI-RE1-1 bypass CLOSED

HV-RE1-8 Process air supply to AW Tank Farm OPEN*

HV-RE1-8A R-E-1 air outlet OPEN*

HV-RE1-21 PSLL-RE1-2 Isolation OPEN

HV-RE1-22 PI-RE1-1 Isolation OPEN

HV-IA-RE1-1 PCV-RE1-1 inlet OPEN

HV-IA-RE1-5 PCV-RE1-1 outlet OPEN

HV-PA-AW-1 AW Farm Isolation valve CLOSED



HV-PA-POR-1 Portable Air Compressor Isolation valve CLOSED

HV-PA-POR-2 Portable Air Compressor Isolation valve CLOSED





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Checklist 4 - Air Receiver R-E-1 Re-pressurization Valving - Startup

Valve Number Description Valve Position Operator Initials

HV-RE1-3 R-E-1 drain trap bypass CLOSED

HV-RE1-4 R-E-1 strainer CLOSED

HV-RE1-10 Process air connect (capped) CLOSED

HV-RE1-13 FI-RE1-1 bypass CLOSED

HV-RE1-8 Process air supply to AW Tank Farm CLOSED

HV-RE1-8A R-E-1 air outlet CLOSED

HV-IA-RE1-3 Hose connection supply valve CLOSED

HV-IA-RE1-4 PCV-RE1-1 bypass CLOSED

HV-RE1-1 Supply air to HV-CPE1-2/CPE2-2 OPEN

HV-RE1-2 R-E-1 drain trap inlet OPEN

HV-RE1-5 R-E-1 drain trap outlet OPEN

HV-RE1-6 FI-RE1-1 inlet OPEN

HV-RE1-7 FI-RE1-1 outlet OPEN

HV-IA-RE1-1 PCV-RE1-1 inlet OPEN

HV-IA-RE1-5 PCV-RE1-1 outlet OPEN

HV-IA-RE1-6 PI-IA-1 supply OPEN

HV-IA-RE1-7 PI-RE1-1 supply OPEN





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Figure 1 - Glycol/Water Compressor Cooler Valving

TK-C-100

1-8

P-C-100

2-33

FV-C100-5

2-242-26

2-28

1-12

2-30

2-2

9

1-10

Floor

Drain

1-9

PI-FC1-1

F-C-1

Filter

Floor Drain

½"

Vent

Line

½"

Sludge

Drain

Line

1-11

HV-RC3-3

1-17

1-16

1-13

2-25

1-13A 1-15

PI-FC1-2

To LERF

TK-241-AW-102

To TK-C-100

FIT

C1

00

-5

Check

Valve

1-15A1-12A

To

PT

-FC

1-4

-1A

Valve Key

Check

Gate

Pressure Regulated

2-Way Ball

3 Way

Ball Valve

PCV-RC3-1

1-211-18

1-19

1-20

PIPC-2

1-55

PIPC-1

1-54

1-28

PIPC-3

1-56

2-35 2-36

1-29

1-27FE-RC3-1

For accuracy and detail,

See Drawing H-2-98990


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Figure 2 - Process Air System Compressors and Air Receiver R-E-1

T

Drain

HV-RE1-5 HV-RE1-2

COMPRESSED AIR SYSTEM

HV-RE1-3

HV-RE1-4

Glycol Out

Glycol In

Oil

Cooler

HV-RE1-1

R-E-1

FIRE-1-1

HC

HV

-RE

1-2

1

HV-RE1-8A

HV-RE1-9

H

PSVRE1-1

ATM

Glycol Out

Glycol In

Oil

Cooler

HV-RE1-13

CP-E-1CP-E-2

Air

Receiver

AW

Farm

HV

-PA

-AW

-1

HV-RE1-7HV-RE1-6

ProcessAir

PI

RE1-1

PSLL

RE1-2

H2

V-R

E1-2

HV

-RE

1-1

0

HC

HV-RE1-8

HV-RE1-12

HV-PA-POR-2

F-CPE1-1

F-CPE2-1F F

HV-CPE2-5

HV-CPE2-7 HV-CPE1-7

HV-CPE1-5

V-P

A-A

W-2

HV-PA-AW-3HV-PA-POR-1

Porta

ble

Air

Com

press

or 1

HV-CP2-1 HV-CP1-1


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Figure 3 - Adding Cooling Oil to Airend


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Figure 4 - Sigma Control Display, Keys/Buttons and Indicators

Item Description Function

1 «ON» Switches on the machine.

The programmed operating mode is active.

2 «OFF» Switches the machine off.

3 «Clock» Switches clock control on and off.

4 «Remote control» Switches remote control on and off.

5 «LOAD/IDLE» Toggles compressor between LOAD and IDLE operating modes.

6 «DOWN» Scrolls down the menu options.

Reduces a parameter value.

7 «UP» Scrolls up the menu options.

Increases a parameter value.

8 «escape» Returns to the next higher menu option level.

Exits the edit mode without Saving.

Returns to the main menu when held down at least 10 seconds.

9 «enter» Only affects the value in the third line of the display.

Enters the selected menu option.

Exits the edit mode and saves.

10 «Events & Information» Displays the event memory.

Selection is possible from every menu.

Return with “esc” key/button.

11 «Acknowledge/Reset» Signifies recognition of alarms and warning messages.

Resets the event memory (When Permitted).

Figure 4 continued on next page.


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Figure 4 - Sigma Control Display, Keys/Buttons and Indicators (Cont.)

Item Description Function

12 Display field Alphanumeric display with 4 lines.

13 Alarm Flashes red when an alarm occurs.

Lights continuously when acknowledged.

14 Communication Lights red if communication via the profibus interface is interrupted.

15 Warning

and

Maintenance

Flashes yellow for:

● maintenance work due,

● warning messages.

Lights continuously when acknowledged.

16 Controller power Lights green when the power supply to the controller is switched on.

17 LOAD Lights green when the compressor is running under LOAD.

18 IDLE Lights green when the compressor is running in IDLE.

Flashes when the «LOAD/IDLE» toggle key/button is pressed.

19 Machine ON Lights green when the machine switched on.

20 Clock The LED lights when the machine is in clock control.

21 Remote control The LED lights when the machine is in remote control.


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Figure 5 - Sigma Control Main Menu Overview

100 psi 80 ºF

key -OFF ¦ p1 – off total 13000 h load 12034 h ↕

100 psi 80 ºF ------------------------- off

------------------------- ↕

PASSWORD

CLOCK

CONFIGURATION

COMPONENTS

PACKAGE TEST

COMMUNICATION

LANGUAGE

STATUS

ANALOG DATA

OPERATING DATA

MAINTENANCE

MESSAGES

STATISTICS

PRINT

esc


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Figure 6 - Configuration Menu Tree

Configuration

- general

version

model:

PN:

SN:

weekday: ……

date: ……

time: ……

summer/winter

date format:

time format:

unit of pressure:

unit of temperature:

- pressure settings

● compressor

pRV

pressure increase

nominal pressure

setpoint pressure p1


system pressure low

cut-in pressure minimum

● vacuum package

system pressure high



pressure fall

● load control

- load control

local mode

remote mode

remote key: y/n

- settings

p1/p2 clock, p1/p2

cycle, p1/p2 RC,

idle load,

local-load RC

venting mode

- idle key active: y/n

esc

To “COMPONENTS” Menu

To “CLOCK” Menu

- control mode

control mode :> …...

settings:

Dual

Quadro

Vario

unload period

refrigeration dryer

modulating valve

- compressor start

compressor ON

local mode:

key, key+clock

clock key: y/n

remote mode:

key+clock, RC

remote key: y/n

clock key: y/n

remote contact:

input

compressor OFF

venting: y/n

holidays

holiday period

- reset

remote mode

remote key: y/n

input

- I/O periphery

- binary output function

- show quantities

- external messages

- switch

- analog output parameter

- timer

OFF

ON

output

= ENTER/RETURN key: initiates move to the next sub menu and enters parameters and passwords.

= ESCAPE key: returns to the next higher level or to the main menu.

esc

= UP ARROW key: scrolls text display downwards.

= DOWN ARROW key: scrolls text display upwards.

i = INFORMATION key: calls up additional information or the event memory.

Bold Text: can be changed by pressing ENTER key Normal Text: can be read only


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Signature Sheet 1

Participating personnel enter their signature, printed name (first & last), and initials below.

Signature Printed Name (First & Last) Initials


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Attachment 1 – Alarm Messages for Machine Shutdown

Basic Information

There are three types of fault:

● Alarm: Red LED flashes – See chapter vendor manual chapter 9.2.

● Warning: Yellow LED flashes - See chapter vendor manual chapter 9.3.

● Other faults: No indication - See chapter vendor manual chapter 9.4.

Sheet 1 of 4

Message Possible cause Remedy

blowoff prot.

The activating pressure of the safety relief valve on

the oil separator tank has been exceeded.

Change the oil separator cartridge.

Open the shut-off valve in the venting line.

sh.cct.AI1

sh.cct.AI2

The connection between the sensor and the analog

input is shorted.

Check line and connections.

AI3/AI4 error Line-break between analog input and the sensor.

Short circuit to earth.


sh.cct.AI5

sh.cct.AI6

The connection between the sensor and the analog

input is shorted.


AI7/AI8 error Line-break between the analog input and the sensor.

Short circuit to earth.


Model Machine model uncertain. Call authorized KAESER Service representative.

bus alarm The bus link from the Profibus DP interface is

defective.

Check line and settings.

PD

Package discharge temperature too low. Call authorized KAESER Service representative.

PD-

Package discharge temperature too high. Check the cooling oil level.

Clean the cooler.

Check the fan motor.

DO0.6/DO0.7 I

Short circuit in the line between the digital output and

the consumer. Check line and connections.

DO1.6/DO1.7 I

Short circuit in the line between the digital output and

the consumer. Check line and connections.


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Attachment 1 – Alarm Messages for Machine Shutdown (Cont.)

Sheet 2 of 4


Airend rotation The motor is turning in the wrong direction. Change over phase lines L1 and L2.

error: RS-485-USS SFC machine with USS protocol:

RS485 transmission

SIGMA CONTROL frequency converter fault

Check the connection between the frequency

converter and SIGMA CONTROL.

Check configuration of the RS485.

Call authorized KAESER Service representative.

ext. message 0

ext. message 1

ext. message 2

ext. message 3

ext. message 4

ext. message 5

Customer specific:

No adjustments possible.

-

back pressure Back pressure in the oil separator tank caused by

defective venting.

Check venting line.

HT cell Fault in the high tension cell. Call authorized KAESER Service representative.

V-belts ruptured The drive belts have parted during machine operation Replace drive belts.

no press. buildup Machine produces no compressed air.

The setpoint pressure does not rise above 50 psig for a

preset period

Check machine for leaks.

Check coupling/V-belts


Condensate drain The condensate drain is defective. Check the condensate drain.

coolingwater low Cooling water pressure too low. Check cooling water supply.

Cooling water throttling valve: check setting.

RD p

Pressure switch for the refrigerant compressor has

activated. Keep ambient conditions within specified limits.

Clean the refrigerant condenser.

Clean the cooler.

RD T

Temperature in the refrigeration dryer too high. Ensure adequate ventilation.


Clean the cooler.

Install an extractor fan.

Fan M2 I

Overload shutdown of the first fan motor Investigate cause of shutdown.

Reset overload trip.


Fan M3 I

Overload shutdown of the second fan motor Investigate cause of shutdown.




Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

47 of 53


Sheet 3 of 4


fan M4 I

Overload shutdown of the third fan motor Investigate cause of shutdown.



fan M7 I

Overload shutdown of the control cabinet fan motor Investigate cause of shutdown.


motor I

Overload shutdown of the compressor drive motor. Investigate cause of shutdown.



motor T

Drive motor overheated. Clean the motor.

Keep ambient conditions within specified limits.

motor bearings Drive motor bearings overheated. Grease the motor bearings.


mains cont. on? Mains contactor not pulling in. Check mains contactor and wiring.

mains cont. off? Mains contactor not dropping out. Check mains contactor and wiring.

mains voltage

2nd power failure. Check power supply voltage.

Check door interlock switch.

mains monitor Fault in mains power supply. Have the mains power supply checked.

Emergency stop EMERGENCY STOP button pressed. Unlatch the pushbutton.

OST dp

Oil separator cartridge clogged. Change the oil separator cartridge.

OST T

Maximum air temperature at the oil separator tank

outlet is exceeded. Check the line to the trip relay.

Oil p

No changeover to LOAD as long as the minimum oil

pressure is not reached.

Check the oil circuit.

Check pressure switch, line, and connection.

p-switch Customer specific:

no adjustments possible. -

pRV

The activating pressure of the oil separator tank safety

relief valve has been exceeded. Change the pressure relief valve.

FC Frequency converter fault Call authorized KAESER Service representative.

SIGMA CONTROL T


Control cabinet: check filter mat and fan.

Softstart Fault in the soft start equipment Call authorized KAESER Service representative.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

48 of 53


Sheet 4 of 4


start T

Airend discharge temperature (ADT) too low.

Ambient temperature: < +36 F Keep ambient conditions within specified limits.

T switch Customer specific:

no adjustments possible. -

ADT

The airend discharge temperature (ADT) did not reach

the minimum required level within the specified time.


ADT

Maximum permissible airend discharge temperature

exceeded.


Clean the cooler.

Check the cooling oil level.

ADT dT/dt Airend discharge temperature rising too quickly. Check the cooling oil level.


access doors Door opened/panel removed while the machine is

running.

Fit and secure all panels and close access doors.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

49 of 53

Attachment 2 – Warning Messages (Yellow Lights)

Sheet 1 of 4 Message Possible cause Remedy

blowoff prot.

The blowoff pressure of the safety relief valve

will soon be reached.


Open the shut-off valve in the vent-ing line.

bus alarm The bus link from the Profibus DP in-terface is

interrupted.

Check bus highway and plug.

PD temperature

Package discharge temperature too low. Call authorized KAESER Service

representative.

PD temperature

Package discharge temperature too high. Clean the cooler.


elect. equip. h

The maintenance interval for checking electrical

equipment and wiring has expired.

Carry out the check and reset the maintenance

interval counter.

error: FEPROM Internal controller memory error. Call authorized KAESER Service

representative.

error: RS 485-PP Wrong configuration or transmission error. Check the link/interface connections between

the two controllers.

Check maximum cable length and screening.

1 master and 1 slave configured.

error SMS SMS can not be sent. Call authorized KAESER Service

representative.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

50 of 53

Attachment 2 – Warning Messages (Yellow Lights) (Cont.)

Sheet 2 of 4


ext. message 0

ext. message 1

ext. message 2

ext. message 3

ext. message 4

ext. message 5

Customer specific:


-

FC AI1 fault SCF machine:

Network pressure sensor on AI1 defective. Call authorized KAESER Service representative.

FC MM Service SCF machine:

Service mode for frequency converter.

Deactivate the service mode as soon as setting of

the frequency converter is complete.

FC mains SCF machine:

Failure of power supply to the frequency

converter.

Check power supply

annual maint Last maintenance was one year ago. Carry out the necessary maintenance and reset the

corresponding maintenance interval counter.

no press. buildup The compressor cannot build-up to working

pressure.

Check for air leaks

Check the value for internal pressure given in the

menu against the reading on the oil

separator tank pressure gauge.

condensate drain. The condensate drain is defective. Check the condensate drain and drain line.

RD T

Refrigeration dryer:

Compressed air temperature too low.


RD p


Pressure in the refrigerant circuit too low.

Inlet pressure switch tripped.


RD p


Pressure in the refrigerant circuit too high.

Safety pressure switch tripped.



Check the fan motor.


bearing.maint. h

The maintenance interval for greasing the

bearings has expired. Grease the motor bearings.

ext.load signal? External load signal indistinct:

Increased cut-out pressure exceeded.

The external load control has not switched to idle

(off load)

Check settings of the external controller. Take into

account pressure drops across filters and dryers.

air filter dp

Air filter clogged. Air filter maintenance.

air filter dp

Air filter clogged. Air filter maintenance.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

51 of 53


Sheet 3 of 4


air filter h

Maintenance interval for air filter cleaning has

elapsed.

Check the air filter.

modem problem SIGMA CONTROL does not recognize the

modem.

Check the link between SIGMA CONTROL

and the modem.

motor T

Drive motor overheating. Clean the motor.

Keep ambient conditions within specified

limits.

motor starts /h

The permissible number of motor starts was

exceeded in the last 60 minutes.

Extend the idle period.

Increase capacity of air receiver.

Increase cross-section of piping between

compressor and air receiver.

motor starts /d

The permissible number of motor starts was

exceeded in the last 24 hours.

Extend the idle period.

Increase capacity of air receiver.

Increase cross-section of piping between

compressor and air receiver.

bearingchange h

The maintenance interval for checking the

bearings has expired.

Have the motor bearings checked by an

authorized KAESER Service representative.

system press.

Network pressure has fallen below the ‘low’

value.

Air consumption too high.

Check air demand.

Check transducer connections and wiring.

Check the ‘systpress. low’ warning setting.

system press.

Network pressure is above the ‘sys,press. high’

value.

Check for air leaks.

Check the ‘systpress. high’ warning setting.

Check if the machine switches to LOAD.

mains voltage

1. Power failure:

machine was re-started automatically.

Check power supply.

Check the door interlock switch.

separator dp

The pressure drop across the oil separator

cartridge has risen.

Oil separator cartridge clogged.


separator h

The interval for the next oil separator cartridge

check has expired.


oil filter dp

The pressure drop across the oil filter has risen.

Oil filter clogged.

Change the oil filter.

oil filter h

The interval for the next oil filter check has

expired.

Change the oil filter.

oil level

Cooling oil level too low. Top up the cooling oil.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

52 of 53


Sheet 4 of 4


oilT

Cooling oil temperature too low. Check temperature switch, line and connection.

Check the oil circuit.

Increase room temperature.

oil change h

The interval for the oil change has expired. Change the cooling oil

p-switch Customer specific:

no adjustments possible.

-

buffer battery Data retention battery id insufficient.. Change the battery.

error: RAM Internal RAM defective. Call authorized KAESER Service

representative.

oil content

The compressed air oil content limit will soon be

reached.

Check the scavenge tube in the oil separator

cartridge.

Check the dirt trap strainer in the scavenge line.

Check air treatment upstream of the measuring

point.

V-belt tension Belt tension is too low. Re-tension drive belts.

bit.coup.insp.h

The maintenance interval for V-belt

tension/coupling inspection has expired.

Carry out visual check.

Re-tension drive belts.

start T

The airend temperature is too low (< +14 F) for

the machine to be operated.

Keep ambient conditions within specified

limits.

start T

The airend temperature is too low (< +36 F) Keep ambient conditions within specified

limits.

set output The ‘set output’ test function is activated. Stop the ‘set output’ mode.

T switch Customer specific:


-

TRAP interrupt System message:

TRAP interrupt

Call authorized KAESER Service

representative.

ADT

Airend discharge temperature has almost reached

maximum.

Clean the cooler.


Replace oil filter.

Ensure adequate ventilation.

Keep surrounding temperature within

recommended limits.

access doors Door opened with the machine stopped. Close access doors.


Type


TO-620-160 Rev/Mod

O-5 Release Date

09/26/2018 Page

53 of 53

Attachment 3 – Other Faults


Machine runs but produces

no compressed air

Inlet valve not opening or only opening partially. Call authorized KAESER Service

representative.

Venting valve not closing. Call authorized KAESER Service

representative.

Leaks in the pressure system. Check pipework and connections for leaks and

tighten any loose fittings.

Air consumption is greater than the capacity of

the compressor.

Check the air system for leaks.

Shut down the consumer(s).

Hose coupling or maintenance hose still plugged

into the quick-release coupling on the oil

separator tank

Remove coupling or maintenance hose.

Cooling oil runs out of the

air filter.

Oil level in the oil separator tank too high. Drain off oil until the correct level is reached.

Inlet valve defective. Call authorized KAESER Service

representative.

Compressor switches

between LOAD and IDLE

more than twice per

minute.

Air receiver too small. Increase size of air receiver.

Airflow into the compressed air network

restricted.

Increase air pipe diameters.

Check filter elements.

The differential between cut-in and cut-out

pressure is too small. Check switching differential.

Cooling oil leaking into the

floor pan.

Hose coupling or maintenance hose still plugged

into the quick-release coupling on the oil

separator tank

Remove coupling or maintenance hose.

Oil cooler leaking. Call authorized KAESER Service

representative.

Leaking joints. Tighten joints.

Replace seals.

Cooling oil consumption

too high.

Unsuitable oil is being used. Use SIGMA FLUID cooling oil.

Oil separator cartridge split. Change the oil separator cartridge

Oil level i