Компрессор kaeser руководство по эксплуатации

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  Operator Manual Screw Compressor M100 No.: 9_6999 23 USE Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com…
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  Original instructions /KKW/M100 2.03 en Z1 SBA-MOBILAIR 20150112 161243…

• Page 3: Table Of Contents

  Fuel recommendation ………………2.6.4 Recommended Cooling Fluid …………….2.6.5 Fluid volumes …………………. 2.6.6 Battery …………………… Options ……………………..2.7.1 Air treatment options ………………. 2.7.2 Low temperature equipment …………….2.7.3 Generator (50 Hz version) ……………… Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Options for operating in fire hazard areas …………4.7.5 Generator option ………………..4.7.6 Transport options ………………..4.7.7 Sealed floor pan option ………………4.7.8 Optional anti-theft device ………………. 4.7.9 Pedestrian protection option …………….4.7.10 Instrument panel cover option …………….Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  9.2.2 Engine does not reach full speed …………… 9.2.3 Indicator lamp remains on ……………… Compressor faults and alarms ………………9.3.1 Working pressure too high ……………… 9.3.2 Working pressure too low………………. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  10.8.7 Engine air intake shut-off valve maintenance …………. 168 10.8.8 Generator drive belt maintenance …………..169 10.8.9 Draining liquid accumulation within the machine ……….172 10.9 Documenting maintenance and service work …………..Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.1 Note the nameplate ………………….175 11.2 Ordering consumable parts and operating fluids/materials ……….175 11.3 KAESER AIR SERVICE ………………..176 11.4 Service Addresses ………………….176 11.5 Replacement parts for service and repair ……………. 176 Decommissioning, Storage and Transport 12.1 De-commissioning ………………….
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  Contents Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Fuel filter with water trap maintenance ………………116 Fig. 52 Changing the fuel pre-filter………………….117 Fig. 53 Fuel micro-filter maintenance ………………… 117 Fig. 54 Checking the engine oil level …………………. 119 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Safety sign — secure the chocks ………………..Fig. 106 Transporting using a forklift truck ………………..242 Fig. 107 Guys to secure the freight ………………….243 Fig. 108 Identification ……………………..245 Operator Manual Screw Compressor viii M100 No.: 9_6999 23 USE…
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  Compressed air delivery with generator in operation (generator with FAD limitation) ….Tab. 50 Connection sockets ……………………Tab. 51 Circuit breaker ……………………..Tab. 52 Generator operating limits ………………….Tab. 53 Maximum three-phase mains loading ………………Tab. 54 Maximum single-phase mains loading ………………Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Maintenance intervals and regular maintenance tasks ………….. 101 Tab. 87 Regular machine maintenance tasks ………………102 Tab. 88 Regular maintenance task options ………………… 104 Tab. 89 KAESER coolant mixture table ………………..108 Tab. 90 Maintenance log ……………………. 174 Tab. 91 Compressor consumables ………………….175 Tab. 92 Consumable engine parts ………………….

• Page 13: Regarding This Document Using This Document

  Copyright This operator manual is copyright protected. Queries regarding use or duplication of the documen‐ tation should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document.

• Page 14: Potential Damage Warnings

  The conditions relevant to safety shown here will help you to avoid dangerous situations. ➤ This symbol is placed by lists of actions comprising one stage of a task. 1. For instructions with several steps … 2..the sequence of actions is numbered. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  The cause is named in the help text … ➤ … and a remedy given. This symbol refers to important information or measures concerning environmental protec‐ tion. Further information Further topics are introduced here. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 16: Technical Data Nameplate

  ■ On the front of the machine (see chapter 13.1) The following table lists all possible options. Only the codes for those options fitted on the machine appear on the nameplate. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 17: Compressed Air Treatment Devices

  Technical Data Options M100 Part Number Serial no. Options fitted hc hd ca cb bb bc bd ga gb r1= rb; rc; rd r3= rm; ro r4= rr; rs; rt r5= rw; rx pa pb 02-M0277 *r1 — r5 = place holders for chassis options Tab.

• Page 18: Check Valve Function

  Option la, lb Equipment for fire hazard areas Option Option code Available? Spark arrestor Spark arrestor and engine air intake shut-off valve (automatic) Tab. 11 Optional equipment for fire hazard areas Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 19: Battery Isolating Switch

  Without height adjustment Service brake (rs): With overrun brake Tab. 13 Chassis options Stationary frame Chassis Option code Available? Stationary (rw, rx): on skids on frame Tab. 14 Options, stationary frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 20: Lighting

  Option sf Anti-theft device Option Option code Available? Anti-theft device Tab. 18 Anti-theft device option 2.2.14 Option sg Pedestrian protection Option Option code Available? Pedestrian protection Tab. 19 Pedestrian protection option Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 21: Instrument Panel Cover

  Instrument panel cover options Machine (without options) 2.3.1 Sound pressure level Sound pressure levels comply with the American EPA Standard. Measurement distance: 23 ft M100 Guaranteed sound pressure level [dB(A)] Tab. 21 Sound pressure level 2.3.2 Tightening torques for screws Recommended values for screws of property class 8.8…

• Page 22: Chassis

  [%] Cross-section width Radial design Use the following table for detailed information regarding the tires of your machine: Characteristic/marking Value Axle load high Tire size 185 R 14C 195 R 14C Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 23: Wheel Nut/Bolt Tightening Torque

  FAD as per ISO 1217:2009. Annex D Tab. 28 Working pressure and FAD 2.5.2 Compressed air outlet Outlet valve [«] Number G 3/4 G 1 1/2 Tab. 29 Compressed air distributor Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 24: Safety Relief Valves

  Airend discharge temperature 2.5.5 Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 25: Tab. 33 Cooling Oil Recommendations

  Viscosity at 50.7 mm 70.0 mm 104 °F (D 445; ASTM test) (D 445; ASTM test) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 26: Cooling Oil Charge

  Oil consumption relative to fuel consumption [%] approx. 0.5 Tab. 36 Engine specification 2.6.2 Oil recommendation The engine oil must meet the following classification: ■ ACEA, class E4, E7 ■ API, class CF, CI-4 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 27: Fuel Recommendation

  The engine service manual gives further information on coolant application. 2.6.5 Fluid volumes Description Fluid volume [gal] Engine oil Fuel 39.63 Coolant 4.23 Tab. 38 Fluid volumes 2.6.6 Battery Feature Value Voltage [V] Capacity [Ah] Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 28: Options

  ■ Cyclone separator ■ Filter combination da + dd + db ■ After-cooler technically oil-free and warmed ■ Cyclone separator ■ Filter combination ■ Heat exchanger Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 29: Low Temperature Equipment

  Antifreeze protection for air brake systems 0.32 (e.g., Wabcothyl) Tab. 45 Recommended antifreeze 2.7.2.4 Option bd Battery Feature Value Voltage [V] Capacity [Ah] PTC testing current [A] (according to EN 50342) Tab. 46 Battery, low-temperature equipment Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 30: Generator (50 Hz Version)

  13.0 [kVA] 8.5 [kVA] Maximum working pres‐ sure [psi] FAD [cfm] − generator FAD cfm] − generator ON Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 31: Tab. 49 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)

  Tab. 51 Circuit breaker Operating limits: (to EN 60034-22, page 10, table) Features Value Design category Voltage adjustment range [%] ±5 Static voltage deviation [%] Maximum dynamic voltage drop [%] –15 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 32: Tab. 52 Generator Operating Limits

  Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 55 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 33: Generator (60 Hz Version)

  Generator 8.0 [kVA] Maximum working pres‐ sure [psig] Free air delivery [cfm] FAD with simultaneous generator operation [cfm] Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 34: Tab. 58 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)

  Maximum voltage settling time [ms] 1500 Maximum voltage asymmetry [%] Tab. 61 Generator operating limits Maximum power loading by consumers Resistive consumers include lamps and heaters, for example. Electric motors and transformers are inductive consumers. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 35: Tab. 62 Maximum Power Supply Load

  Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 63 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 36: Safety And Responsibility Basic Instructions

  ➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in effect. User’s Responsibilities 3.4.1 Observe statutory and universally accepted regulations ➤ Observe relevant statutory and accepted regulations during operation, transporting and main‐ tenance of the machine. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 37: Determining Personnel

  This regulation requires that machines filled with more than 0.26 gallons petrol or 1.32 gallons die‐ sel (in the fuel tank) during transport must be identified with hazardous goods labels on the ma‐ chine’s exterior. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 38: Dangers

  ➤ Do not allow fuel to overflow. ➤ Wipe up spilled fuel immediately. ➤ Provide a fire extinguisher in the immediate vicinity. ➤ For operation in combustible environment, fit the machine with an exhaust silencer (Option la). Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. Minimum pressure / check valves, safety relief valves, and inlet valves are powerfully spring-loa‐ ded. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  ➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine.

• Page 41: Safe Machine Operation

  Dangers ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER pressure components. Conversion or modification of the machine Modifications, additions or conversions to or of the machine can result in unpredictable hazards.

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  ➤ Do not position the machine directly against a wall. A build up of heat from the exhaust can damage the machine. ➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  ➤ De-pressurise all pressurised components and enclosures. ■ Wait until the machine has automatically vented. ■ Carefully open the compressed air outlet valve. ■ Check: The pressure gauge must read 0 psig! Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 44: Organizational Measures

  ➤ Do not open the body while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Operate the machine only in technically sound condition.

• Page 45: Danger Areas

  More information on safety devices is contained in chapter 4.5. Safety signs The diagram shows the positions of safety signs on the machine. The table lists the various safety signs used and their meanings. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 46: Fig. 2 Location Of Safety Signs

  ➤ Always wipe up fuel spills which may occur inside the compressor enclo‐ sure and allow the machine to ventilate. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  ➤ Food grade coolant must be used for food processing. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 48: Tab. 65 Safety Signs

  Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded. ➤ Never open (dismantle) valve. ➤ Contact an authorized KAESER service representative. 830**** There is danger of fatal injury touching electrically live components! ➤…

• Page 49: Noise Control Requirements

  ➤ Only a qualified electrician is allowed to carry out work on the generator or generator control box. The electrician is responsible for the effectiveness of the protective measures provided. ➤ Do not use the generator for feeding the construction current distribution. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 50: Connecting Extension Cables

  ➤ Check and tighten the screw connections at the generator and the generator control cubicle. ➤ Check covers and power socket caps for damage and good sealing. ➤ Check the completeness of labeling and warning labels. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 51: Emergencies

  Skin contact Fuel, oil and other fluids/materials may irritate after prolonged contact. ➤ Wash thoroughly with skin cleaner, then with soap and water. ➤ Contaminated clothing should be intensively cleaned before reuse. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 52: Warranty

  ■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11.1 Noise emissions warranty The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built, and equipped to conform, at the time of sale to the first retail pur‐…

• Page 53: Environmental Protection

  ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐ mental protection regulations. ➤ Observe relevant regulations. This applies particularly to parts contaminated with fuel, oil, coolants and acids. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 54: Design And Function Bodywork

  Safe and reliable operation is only ensured when the bodywork is closed. The wing doors are provided with handles for opening. Release the doors by the snap fasteners. The doors are held open by gas springs. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 55: Component Identification

  Pressure relief valve Tool box Lifting eye cover Airend Lifting eye Inlet valve Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 56: Fig. 6 Machine Layout

  . The minimum pressure / check valve ensures that there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the ma‐ chine. The cooling fan ensures optimum cooling of all components within the enclosure. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 57: Operating Modes And Control Mode

  This stepless delivery regulation minimises fuel consumption of the engine. The load and fuel con‐ sumption of the engine rises and falls with the air demand. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 58: Safety Devices

  Safety devices 4.5.1 Monitoring functions with shutdown The following functions are monitored automatically. ■ Engine oil pressure ■ Coolant temperature ■ Airend discharge temperature ■ Fuel level ■ Engine alternator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 59: Further Safety Devices

  (red) to indicate an alarm. The alarm is saved and the engine cannot be restarted. You can restart the machine only after deactivating and refilling the machine. Options The options available for your machine are described below. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 60: Compressed Air Treatment Options

  The oil/air heat exchanger is fed with hot compressor cooling oil that warms the outgoing moisture- reduced compressed air. This warm, dry compressed air is ideal for sand blasting, for example. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 61
  The oil flow can be stopped by a shut-off valve. The oil flow adjusts automatically to changes in air demand (one or more tools/consumers on line). Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 62: Fig. 10 Tool Lubricator

  Fig. 11 Principle tool lubricator Compressed air inlet Tool lubricator upper part with oil filling port Oil tank Filler plug with dipstick and integrated riser Tool oil outlet tube Metering knob Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 63: Low Temperature Equipment Options

  Option bc Frost protection Control air is mixed with an alcohol-based antifreeze to prevent control and regulating devices freezing. This considerably lowers the freezing point of any moisture in the air. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 64: Optional Battery Isolating Switch

  Damage to the machine’s electrical components is possible. ➤ Use the «battery isolating switch» only when the machine is shut down. ➤ Do not use the «battery isolating switch» as a main or emergency switch. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 65: Options For Operating In Fire Hazard Areas

  A spark arrestor on the exhaust silencer is required when operating a diesel engine in a fire hazard area and in forestry and agricultural applications. In such applications, a spark may ignite flamma‐ ble materials. The spark arrestor prevents the exhaust silencer emitting any glowing fuel residue. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 66: Generator Option

  Engine run-on time of approximately 2 mi‐ nutes at maximum speed Advantages Fuel saving Continuous generator power Constant oscillation between maximum and available without delay minimum speed avoided Tab. 67 Generator operating modes Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 67: Fig. 15 Instrument Panel — Generator Control Box, 400 V Ac

  Instrument panel – generator control box, 230 V AC «Mode selector switch» Generator control box 32 A three-phase power socket «Generator main switch» Single-phase power sockets «Safety cut-out» 16 A three-phase power socket «Safety cut-out» (with overcurrent release) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 68: Transport Options

  Option rb/rk/rm/rs Chassis Option rb — chassis EU version Option rk — Chassis with low axle load Option rm — chassis with height-adjustable tow bar Option rs — chassis with overrun brake Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 69
  Option rb/rl/rm/rs Chassis Option rb — chassis EU version Option rl — Chassis with higher axle load Option rm — chassis with height-adjustable tow bar Option rs — chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 70: Sealed Floor Pan Option

  When other components are removed from the sealed floor pan, (for example the sheet metal cover) they must be properly re-sealed prior to installation. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 71: Optional Anti-Theft Device

  The machine is fitted with a security chain as theft protection. 4.7.9 Option sg Pedestrian protection option The machine is fitted with a special protective guard that prevents pedestrians from being run over. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 72: Instrument Panel Cover Option

  To prevent unauthorized use and as protection during transport the machine is fitted with instru‐ ment panel cover(s). ■ Instrument panel cover (option pa) ■ Generator control box cover (option ga) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 73: Installation And Operating Conditions

  Installation conditions Precondition The floor must be level, firm and capable of bearing the weight of the machine. Fig. 21 Minimum distance from excavations/slopes and walls Wind direction Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 74
  ➤ Use winter grade engine oil. ➤ Use winter diesel fuel. ➤ Use low viscosity compressor cooling oil. 10. At ambient temperatures below 32 °F, follow the instructions in chapter 7.4. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 75: Installation

  Precondition The machine is standing firm and level. The machine is switched off. Danger of pinching! Severe pinching injury to fingers is possible. ➤ Always wear protective gloves. ➤ Work carefully. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 76: Fitting The Height Adjustable Towbar

  Manually tighten the locking lever. ■ Use a hammer to hit the locking lever to further tighten the lower serrated joint until the bore and the groove for the splint pin are aligned Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 77: Fitting A Non-Adjustable Tow Bar

  2. Remove the bag with the brake transfer cable and fastenings, unpack and lay out ready. 3. Close the doors. 4. Remove all transport securing items (screw fastenings, duct tape, foam pads) from the tow bar components. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 78: Fig. 25 Fitting The Overrun Braking Mechanism Of The Non-Adjustable Tow Bar

  6. Screw the the brake-rod linkage onto the rear screw fastening of the brake transfer cable and secure with a lock nut. Further information Further information on setting the brake actuating rod is to be found in chapter 10.7.3.3. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 79: Adjusting The Chassis

  The machine is disconnected from the towing vehicle and safely parked. Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤ Always wear protective gloves. ➤ Work carefully. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 80: Adjusting The Towbar Height

  The serrated joint will not disengage. The serrations are corroded together. ➤ Free the serrations by jerking the towbar horizontally and vertically. 6.4.2 Changing the towing eye/ball hitch The towbar can be fitted with various towing eyes or couplings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 81: Fig. 28 Changing The Towing Eye (Height-Adjustable Drawbar)

  2. Unscrew the nuts of both screw connec‐ 2. Remove the coupling from the towbar tions and withdraw the bolts 3. Remove the towing eye from the tow‐ Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 82: Fig. 29 Changing The Towing Eye/Ball Hitch (Fixed Height Towbar)

  Fig. 29 Changing the towing eye/ball hitch (fixed height towbar) Self-locking hexagon nut Towbar Hex-head screw Shock absorber Shock absorber fixing eye Mounting pin Hex-head screw Ball coupling Protective sleeve Towing eye Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 83: Fig. 30 Changing The Towing Eye (Fixed Height Towbar, Usa Chassis Version)

  10. Draw the protective sleeve over the fixings. Checking the overrun braking mechanism ➤ Push the towbar tube in and out by hand. If resistance is felt, the shock absorber is properly connected. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 84: Initial Start-Up Ensuring Safety

  ➤ Remove all packing materials on and in the machine. ➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐ rectly. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 85: Special Measures For Re-Commissioning After Storage

  ➤ Clean the bodywork with a grease and dirt dissolving agent. ➤ Check the tire pressures. 36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐ ice Technician. Tab. 68 Measures for re-commissioning the compressor after a long period of storage Checking installation and operating conditions ➤…

• Page 86: Low-Temperature Operation (Winter)

  ➤ Observe the instructions provided with the battery jumper cables. ➤ Do not connect the battery jumper cables to the negative pole of the discharged battery or to the bodywork of the machine. ➤ Work with caution. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 87: Fig. 31 Jumper Cable Connection Diagram

  1. Park the assisting vehicle in close distance to the engine, without their bodywork touching each other. 2. Stop the engine of the assisting vehicle. 3. Open the accesses to the batteries (remove maintenance panels/bonnet and pole caps). 4. Switch off all power consumers. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 88: Starting Up Low-Temperature Equipment

  Operating the engine cooling water pre-heater The engine coolant can be pre-heated to improve starting under cold conditions. The connection for the power supply is located on the machine’s instrument panel. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 89: Fig. 32 Engine Coolant Pre-Heating

  Frost protector Ball valve (closed) Level of antifreeze ➤ Use the checklist when initially starting the frost protector. To be checked see chapter Confirmed? Level of antifreeze in the frost protector. 10.8.5 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 90: Activating The Generator

  «Mode selection switch» («Circuit breaker» designed as automatic Test button «Insulation monitor» with indi‐ circuit-breaker with shunt trip) ground short cator light for Three-phase AC power sockets Single-phase AC power sockets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 91: Fig. 36 Insulation Monitoring — 115 V, Single-Phase Generator

  1. Activate the machine. Danger of fatal injury caused by contact with live components! ➤ The generator may only be used if the «circuit breaker» («main circuit breaker») has trip‐ ped during the test! Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 92: Tab. 71 Test Instructions For A Generator With An Ground Short Detection Device

  The «main circuit breaker» trips. Problem: The «main circuit breaker» does not trip out? ➤ Shut down the generator and call your authorized KAESER service representative. Tab. 71 Test instructions for a generator with an ground short detection device. Operator Manual…

• Page 93: Operation

  The hose length represents a cooling section. With increasing cooling, the compressed air gives off moisture capable of damaging the air tool. ➤ Use short compressed air hoses. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 94: Starting And Stopping

  Fuel level monitoring light – On – – Preheat – START LOAD – «Load On» key with integrated mode indicating light Back-pressure indicating light – Charging indicating light, group alarm lamp Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 95: Starting The Machine

  To avoid unnecessary wear, the engine should be run in IDLE until the airend discharge tempera‐ ture reaches +86 °F. The airend discharge temperature is shown at the remote thermometer con‐ tact on the instrument panel. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 96: Switching To Load

  The required pressure can be seen on the gauge on the instrument panel. The pressure setting on the proportional controller can only be lower than the maximum working pressure of the machine. Precondition The machine is switched off. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 97: Shutting Down The Machine

  The engine runs in IDLE and the turbo charger can cool down. 3. After approx. 2 to 3 minutes, switch the «starter switch» to the «STOP/Off» position. The engine turns off. Shutting down the machine: 1. Open the right-hand access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 98: Monitoring Fuel Level In The Fuel Tank

  The machine is switched off. Tool lubricator is filled with oil Fig. 41 Setting the tool lubricator Shut-off valve I – open 0 – closed Metering knob ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 99: Using The Low-Temperature Equipment

  Using the low-temperature equipment ➤ Ascertain which low temperature equipment is fitted to the machine. 8.5.1 Option bb Pre-warms the engine cooling water ➤ Start the engine coolant pre-heating as described in chapter 7.4.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 100: Operating The Machine With Frost Protector

  See chapter 10.8.5 for filling the frost protector with antifreeze. Using with the frost protector switched off Operating at temperatures above 32 °F (summer operation). 1. Leave the frost protector shut-off valve open permanently (position I). 2. Close the door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 101: Operating The Battery Isolating Switch

  ➤ Check correct function of the insulation monitoring device daily (see chapter 7.5). ➤ Have the generator and control box checked annually by a qualified electrician (see chapter 13.9). ➤ Follow instructions in chapter 3.9. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 102: Note When Operating The Generator

  ■ Switch off electrical consumers and unplug them one-by-one. ■ Switch off consumers drawing the highest current last. ■ Check that the protective covers on the power sockets are correctly closed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 103: Cleaning The Machine After Operation

  Water has accumulated in the sealed floor pan. ➤ Drain the water. Catch the liquid and dispose in accordance with applicable environmental regulations. Further information See chapter 10.8.9 for information to the draining of liquids within the machine. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 104: Fault Recognition And Rectification

  1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Observe the instructions in chapter 3 «Safety and Responsibility» and prevailing local safety regula‐…

• Page 105: Engine Does Not Reach Full Speed

  Tighten the connection or have – bles loose or broken the cable replaced. Defective alternator. Have repaired or replaced if – necessary. Defective alternator regulator. Have repaired or replaced if – necessary. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 106: Compressor Faults And Alarms

  Pressure relief valve maladjus‐ Have repaired or replaced if – ted and/or leaking. necessary. Venting valve does not close. Check the connections and – function and have repaired or replaced as necessary. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 107: Pressure Relief Valve Blowing Off

  1 psi. See chap‐ ter 10.4.6 for changing. Compressor oil filter clogged. Change, see chapter 10.4.4. – – Compressor cooling oil level too Topping up, see chapter 10.4.2. – – low. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 108: Too Much Oil Residue In The Compressed Air

  Specialized KAESER workshop Service Defective non-return function of Repair or have replaced if nec‐ – the inlet valve. essary. Tab. 80 Fault: Oil flows from the compressor air filter after shutdown Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 109: High Moisture Content In The Compressed Air

  There is no voltage or too low a voltage from the generator 9.4.2 Generator voltage too high Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Generator / regulator defective Have repaired. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 110
  Generator faults and alarms Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Engine speed too high. Have reset to rated speed. Tab. 83 Generator voltage too high Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 111: 10.1 Maintenance

  The following safety concerns relate to any work on components that could be under pressure. ➤ Disconnect the air consumers. ➤ Depressurize all pressurized components and enclosures. ■ Wait until the machine has automatically vented. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 112: Maintenance Schedules

  10.2 Maintenance schedules 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work (e.g. oil and filter changes) at shorter intervals. Adverse conditions are, e.g.: ■…

• Page 113: Regular Maintenance Tasks

  The table below lists regular maintenance tasks. 1. Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐ ation. 2. Change consumables and operating fluids according to each site. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 114
  Check/empty the water trap. 10.3.3 Check fuel lines and hose clamping bands, have replaced if necessary. Have fuel lines and clamps re‐ placed. Engine SM = engine manufacturer’s service manual; SW = specialized workshop. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 115
  Check wheel bolts and nut for tightness. Carry out chassis maintenance. 10.7 Grease the ball coupling, joints 10.7.2 and towbar. Brake maintenance 10.7.3 Engine SM = engine manufacturer’s service manual; SW = specialized workshop. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 116: Tab. 87 Regular Machine Maintenance Tasks

  Option da, db, dc, dd – cyclone separator Clean and check the dirt trap. 10.8.2 Options da, db, dc, dd – compressed air aftercooler Clean the cooler. 10.5.2 EL = qualified electrician; SW = specialist workshop Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 117: Tab. 88 Regular Maintenance Task Options

  Option oe – sealed floor pan Check the machine interior for 10.8.9 liquid accumulations and drain, if required. EL = qualified electrician; SW = specialist workshop Tab. 88 Regular maintenance task options Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 118: Engine Maintenance

  ■ The tank is semi-transparent so the coolant level can be seen from outside. minimum and maximum markings when the engine has ■ The level should be between the cooled down. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 119: Fig. 44 Checking Coolant Level

  Maximum frost protection is ensured with an antifreeze concentration of 55% by volume, as frost protection and heat transfer properties deteriorate beyond this point. Higher concentration also leads to higher operating temperature. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 120: Tab. 89 Kaeser Coolant Mixture Table

  ➤ Follow coolant recommendations in chapter 2.6.4. Preparing coolant Precondition Coolant must meet the specification of ASTM D4985. ➤ The coolant should be mixed in the proportions given by the manufacturer. KAESER coolant mixture table Antifreeze Water Frost protection to [°F] 1 part 2 parts −0.4…

• Page 121
  In machines with chassis (no closed floor pan, no stationary machine), the entire cooling oil of the cooling circuit is drained directly at the engine’s water cooler. This is done from a drain valve with the aid of a separate drain hose. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 122: Fig. 45 Draining The Coolant From The Radiator

  The cooling oil is drained via a pipe which is screwed into the drain opening of the cooler and closed with a shut-off valve. The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 123: Engine Air Filter Maintenance

  Do not use an air filter element with damaged folds or gasket. ■ The use of an unsuitable air filter can permit dirt to ingress the engine and cause prema‐ ture wear and damage. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 124: Fig. 47 Engine Air Filter Maintenance

  Fig. 47 Engine air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 125: Fig. 48 Cleaning The Filter Element

  The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 126: Fuel System Maintenance

  ➤ Keep fuel away from hot machine parts. Fig. 49 Fuel system maintenance Fuel pump Fuel tank Fuel de-watering filter Fuel strainer Fuel pre-filter Fuel fine filter ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 127: Fig. 50 Bleeding The Fuel System

  Fuel filter with water trap maintenance A water trap is installed between the tank and the fuel pump. The separator tank is semi-transpar‐ ent so the fuel level can be seen from outside. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 128: Fig. 51 Fuel Filter With Water Trap Maintenance

  4. Remove the receptacle. 5. Reconnect the battery. 6. Close the door. The mixture of fuel and water and any materials contaminated with fuel must be disposed of in accordance with environment protection regulations. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 129: Fig. 52 Changing The Fuel Pre-Filter

  2. Use a filter wrench to loosen then unscrew the filter cartridge. Catch fuel in the receptacle. 3. Clean the sealing faces of the micro-filter cartridges and the opposite site of the filter mount with lint-free cloth. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 130: Checking The Engine Oil Level

  The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Engine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 131: Engine Oil Filling And Topping Up

  See chapter 2.6.5 for engine oil filling volume. The oil dipstick is marked with the «maximum oil level». 1. Open the right-hand access door. 2. Remove the filler cap and fill with fresh oil. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 132: Changing The Engine Oil

  All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to the battery is disconnected. Danger of burns from hot components and escaping engine oil! ➤ Wear long-sleeved clothing and protective gloves. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 133: Fig. 55 Draining The Engine Oil

  The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 134: Fig. 56 Draining The Engine Oil (Closed Floor Pan — Stationary Machine)

  Dispose of old oil and oil-soaked working materials according to environmental protection regulations. Further information See chapter 10.3.5 for engine oil filling. Further information regarding changing the engine oil is provided in the engine manufacturer’s op‐ erating manual. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 135: Replace The Engine Oil Filter

  Further information The engine service manual gives further information on oil filter changing. Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐ tal protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 136: Drive Belt Maintenance

  Removing the belt guard: Fig. 58 Belt guard attachment Belt guard Washer Hexagon bolt Hexagon socket screw 1. Unscrew the securing screws of the belt guard and remove the belt guard. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 137: Fig. 59 Checking The Drive Belt Seating

  The belt tension can be checked by hand: To check the tension, press the belt inwards with the thumb at the mid-point between pulleys. Fig. 60 Manually checking the belt tension Drive belt testing position — Compressive load approximately: 22 Kg Play approximately: 0.28 – 0.35 in Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 138: Fig. 61 Changing/Tensioning The Drive Belt

  1. Loosen the alternator securing screw and clamping nut until the drive belt can be taken off the pulleys. 2. Take off the belt. 3. Check the pulleys for dirt and wear. Dirty pulley: Clean pulley. Worn pulley: Have the pulley changed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 139: Battery Maintenance

  When working on the battery comply with the following safety signs: A warning label with safety signs is attached to the battery. Fig. 62 Safety signs — warning stickers on the battery. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 140
  The acid quantity is generally sufficient for the life of the battery. Nevertheless, the fluid level should be checked annually. The level should be up to the mark, 0.4 inches above the plates. Replace the battery immediately if the casing leaks. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 141
  ➤ Carry out work on batteries only with the machine shut down. 3. Open the left-hand door. 4. Disconnect the negative cable first, then the positive cable. 5. Unscrew the battery fixing clamp. 6. Replace in the reverse order. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 142: Checking The Fastening Of The Fuel Tank

  10 daN (approx. 25 lbf), slightly hand-tighten only. ➤ Hand-tighten the lashing strip with the integrated ratchet and push the ratchet to the strip. 10.4 Compressor Maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 143: Checking Cooling Oil Level

  2. Slowly unscrew and withdraw the plug from the oil filler port. 3. Check the cooling oil level. Top up if no oil is visible. 4. Replace the plug in the filler port. 5. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 144: Cooling Oil Filling And Topping Up

  5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 145: Changing The Cooling Oil

  Draining the cooling oil (machine with chassis) In machines with chassis (no closed floor pan, no stationary machine), the cooling oil is drained directly at the oil separator tank and the oil cooler. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 146: Fig. 64 Draining The Compressor Cooling Oil

  1. Replace the plug in the oil separator tank filling port. 2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for cooling oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 147: Fig. 65 Draining The Oil From The Heat Exchanger

  The pipes are sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 148: Fig. 66 Draining The Cooling Oil (Closed Floor Pan — Stationary Machine)

  2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 149: Replace The Compressor Oil Filter

  Top up if necessary. 8. Reconnect the negative battery terminal. 9. Close the access door. Dispose of old cooling oil and any materials or parts contaminated with oil according to envi‐ ronment protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 150: Oil Separator Tank Dirt Trap Maintenance

  The negative cable to the battery is disconnected. Fig. 68 Oil separator tank dirt trap maintenance Oil separator tank cover Nozzle Control valve Screw-in connector Union nut Gasket Oil return line Strainer ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 151: Changing The Oil Separator Cartridge

  The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ and adherence to the changing intervals for: ─ Cooling oil ─ Oil filter ─ Air filter Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 152: Fig. 69 Changing The Oil Separator Cartridge

  2. Pull out the plug to the solenoid valve and withdraw the cable. 3. Unscrew the fitting and turn the air pipe to one side. 4. Remove the screws securing the cover to the tank. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 153
  5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 154: Fig. 70 Changing The Oil Separator Cartridge (Option Ba)

  Take particular care with the following components: ■ The frost protector connected to the control line, ■ The oil scavenge line screwed to the underside of the cover. 7. Take out the old cartridge and gaskets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 155: Compressor Air Filter Maintenance

  Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to be necessary. Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 156: Fig. 71 Compressor Air Filter Maintenance

  Fig. 71 Compressor air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 157: Fig. 72 Cleaning The Filter Element

  The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 158: Checking Safety Relief Valves

  Maintenance 10.5 Cleaning the cooler 10.4.8 Checking safety relief valves ➤ Have safety relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.5 Cleaning the cooler The frequency of cleaning is mainly dependent on local operating conditions.

• Page 159: Cleaning The Compressed Air Aftercooler

  2. Visually inspect for leaks. Does oil or cooling water escape? Is a cooler leaking? ➤ Have the defective cooler repaired or replaced immediately by KAESER Service. ➤ Close the doors. Clean the cooler blades only in a washing area equipped with an oil separator.

• Page 160: Maintenance Of Rubber Sealing Strips

  2. Clean the rubber sealing strips with a lint-free cloth and check for cracks, holes and other dam‐ age. Have any damaged gasket replaced. 3. Properly grease the rubber strips. 4. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 161: Chassis Maintenance

  Clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months. Material Lithium-enriched multi-purpose grease Acid-free oil Cleaning cloth Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 162: Fig. 75 Towbar Maintenance

  ➤ If necessary, free the teeth by jerking the towbar horizontally and vertically. ➤ Clean the toothed coupling and smear with water-repellent grease. Further information See chapter 6.4.1 for towbar height adjustment. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 163: Fig. 77 Ball Coupling (Ec Version)

  ■ Oil leaks out. 10.7.2.3 Ball coupling maintenance Option rb/rk/rm/rs, rb/rl/rm/rs, rc/ro/rs Fig. 77 Ball coupling (EC version) Lubricating points Greasing points Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 164: Brake Maintenance

  2. Turn the wheels in the forward direction. 3. Check that there is the same braking resistance on both wheels. Brake resistance not even: adjust brake system. 4. Release the parking brake. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 165: Fig. 79 Checking The Brake Lining Thickness

  3. Apply the parking brake a number of times to centre the brake linings. 4. Use the screwdriver to turn the adjusting wheel back (3 to 5 notches) until there is no more braking resistance to the wheels turning forward. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 166: Fig. 81 Brake Rod Adjustment

  1. To free the brake rod, remove the hexagon nut at the equaliser and loosen the sleeve 2. Clean and grease the brake rod threads. 3. Manually tighten the connecting sleeve. 4. Pull and release the parking brake three times. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 167: Maintenance For Optional Items

  The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. The machine has cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 168: Fig. 82 Tool Lubricator Maintenance

  2. Use a funnel to pour in the oil to the maximum level (0.4 – 0.6 inches below the top of the tank). 3. Check the oil level. 4. Check the filler plug O-ring for external damage. Skadet O-ring: replace the O-ring. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 169: Cyclone Separator Maintenance

  2. Loosen the union nut and detach the condensate drain hose from the dirt trap. 3. Use the small screwdriver to unscrew the nozzle from the dirt trap housing. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 170: Combination Filter Maintenance

  Filter combination is pressurised during operation. Serious injury can result from loosening or opening components under pressure. ➤ Wait until the machine has automatically vented (check: pressure gauge reads 0 psig! ➤ De-pressurise the combination filter. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 171: Fig. 84 Filter Combination

  Pressure differential gauge (check fittings Microfilter for Service personnel) Pre-filter Filter head Cyclone separator Casing gasket Condensate drain hose fittings Filter element Shut-off ball valve for condensate drain‐ Filter housing ➤ Open the left-hand door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 172
  Changing the prefilter element 1. Unscrew the filter housing counter-clockwise. 2. Draw the filter element down and out. 3. Clean the filter head, housing and sealing surface with a lint-free cloth. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 173
  3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open the left-hand door. 6. Check the combination filter housing and hose lines for leaks. 7. Close the door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 174: Fresh Air Filter Maintenance

  2. Open the condensate drain valve. 3. Close the doors. 4. Switch the machine on and run it in IDLE mode for approx. 2 minutes. The condensate collecting in the filter housings is blown out. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 175
  2. Draw the filter element down and out. 3. Clean the lower housing and sealing surface with a lint-free cloth. 4. Check the housing gasket. When damaged, replace the housing gasket. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 176
  3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open both doors. 6. Check the fresh air filter housing and hose line for leaks. 7. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 177: Frost Protector Maintenance

  Filling the frost protector Frost protector clamp ring Frost protector bowl Antifreeze container 1. Open both doors. 2. Unscrew the clamp ring and remove the bowl. 3. Fill the bowl ¾ full with antifreeze. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 178: Spark Arrestor Maintenance

  Cleaning the spark arrestor (floor pan with service openings) Exhaust silencer end pipe Soot drain port with plug Opening in floor panel to access drain port Exhaust silencer with integrated spark ar‐ restor Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 179: Fig. 89 Cleaning The Spark Arrestor (Sealed Floor Pan)

  7. Remove the hose and replace the plug. 8. Screw the service plug back into the floor pan. It is recommended to blow out the spark arrestor with compressed air once a year. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 180: Engine Air Intake Shut-Off Valve Maintenance

  The machine does not shut down? Destruction of the engine and explosion and/or fire are possible! ➤ Do not move the valve adjusting screw. ➤ Have the valve set by a specialist workshop or KAESER Service. Fig. 90 Engine air intake shut-off valve maintenance…

• Page 181: Generator Drive Belt Maintenance

  Blow out any dirt with compressed air. If necessary, clean the valve with petroleum ether or spirit and allow to dry. Refer to a specialised workshop or KAESER Service if dirt cannot be removed. Checking the engine air intake shut-off valve for correct function and movement: 1.

• Page 182: Fig. 91 Securing The Belt Guard At The Generator

  2. Replace the belt guard. 3. Reconnect the negative battery terminal. 4. Close the doors. 10.8.8.2 Checking belt tension Check belt tension when they are warm, not hot, to avoid length variations through tempera‐ ture. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 183: Fig. 92 Generator Belt Tensioning

  3. Tighten the locknuts 4. Replace the belt guard. 5. Reconnect the negative battery terminal. 6. Close the doors. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 184: Draining Liquid Accumulation Within The Machine

  All compressed air consumers are disconnected and the air outlet valves are open. 1. Place a receptacle underneath the maintenance opening(s). 2. Unscrew and remove the bung(s) from the maintenance openings. The liquid will drain. 3. Clean the bungs and maintenance openings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 185
  4. Close all maintenance openings with bungs. The machine body is sealed. 5. Using the cleaning cloth, remove any dirt within the machine. Dispose of collected liquid and contaminated working materials according to environmental protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 186: Documenting Maintenance And Service Work

  Documenting maintenance and service work Machine model/part number: ➤ Enter maintenance and service work carried out in this list. Date Maintenance task carried out Operating hours Signature Tab. 90 Maintenance log Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 187: 11 Spares, Operating Materials, Service

  11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are match‐ ed to application in our machines and ensure trouble-free operation. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐…

• Page 188: Kaeser Air Service

  Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Replacement parts for service and repair With the help of the parts list you can plan your material requirement according to operating condi‐…

• Page 189
  ➤ Inspections, preventive maintenance or repair tasks not described in this manual must not be carried out by unqualified personnel. ➤ Have further tasks, not described in this service manual, carried out by motor vehicle workshops or KAESER Service. Operator Manual Screw Compressor No.: 9_6999 23 USE…
• Page 190
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 239: 12 Decommissioning, Storage And Transport

  Decommissioning of the compressor for several weeks during severe frost Danger of batteries freezing! Discharged batteries are subject to frost damage and can freeze at 14 °F. ➤ Store batteries in a frost-free place. ➤ Store batteries preferably fully charged. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 240: Long-Term Decommissioning And Storage

  ➤ Clean the bodywork and treat with preservative. – ➤ Hang a notice on the instrument panel to inform of the decommis‐ – sioning measures taken. Tab. 96 Long-term decommissioning and storage checklist Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 241: Transport

  Chassis with overrun brake ■ Lighting and signaling system. All other machines may be transported only on non-public roads! National and local regulations must be observed when towing the machine on public high‐ ways. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 242
  Option rb/rk/rm/rs, Adjust the towing bar to suit the height of the towing vehicle hitch. rb/rl/rm/rs When the machine is coupled up, the towing bar must be parallel with the ground. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 243: Fig. 93 Towing Position

  To hitch up the machine, lower the open coupling onto the ball of the towing vehicle so that it clicks into place. The coupling is fully locked when the green locking indicator protrudes and is visible from the side. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 244: Fig. 94 Ball Coupling (Alko-Eu)

  Checking the ball coupling wear indicator (EU version): The ball coupling is equipped with a wear indicator. The wear indicator shows: ■ Wear on the ball hitch. ■ Wear on the coupling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 245: Fig. 95 Wear Alert, Ball Coupling (Alko-Eu)

  Option rd/ro/rs Coupling machine with ball coupling (US version): To couple up the compressor, lower the open coupling onto the ball hitch of the towing vehicle so that it clicks into place. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 246: Fig. 96 Ball Coupling (Alko-Usa)

  Ensure transport readiness of the coupled machine. Fig. 97 Release the parking brake. Parking brake with gas spring assistance Parking brake with ratchet and spring load‐ Parking brake lever Dead point zone Brake lever release button Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 247: Fig. 98 Automatic Jockey Wheel In Transport Position

  (see Ill. 97, figure b). ■ Pull the brake lever a little further on and press the release button. ■ Hold in the release button and push the lever fully down. 6. Remove the chocks. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 248: Fig. 99 Safety Sign — Secure The Chocks

  5. Attach the lighting and indicator systems and carry out a function check. 6. Remove the chocks and secure them in the transport securing device. Replacement chocks can be purchased from KAESER representatives. A list is given at the end of this manual. The part number of the chock is 5.1325.0.

• Page 249: Fig. 100 Breakaway Cable Attachment

  ➤ Attach safety chains to the towing vehicle. ■ Both chains must be crossed under the ball coupling/towing eye. ■ Allow slack for towed machine to turn. ■ Attach chain hooks securely to tow vehicle frame. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 250: Parking The Machine

  ➤ Wind the automatic jockey wheel up only as far as the bead does not touch the cam. ➤ Do not place your feet beneath the towing device. Fig. 102 Warning «Injury can occur if the towbar is allowed to fall.» Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 251: Fig. 103 Towbar With Automatic Jockey Wheel

  Slowly forward the towing vehicle to separate from the parked machine. Option rb/rk/rm/rs, Parking the machine (height-adjustable chassis): rb/rl/rm/rs 1. Use a coupled towing vehicle to move the machine into position. 2. Disconnect the lighting and signaling cable. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 252: Fig. 105 Safety Sign — Secure The Chocks

  ➤ As a general rule, the machine should always be blocked with chocks when it is not being moved. ➤ The machine should not be manoeuvred by hand. 2. Use a coupled towing vehicle to move the machine into position. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 253: Transport With A Crane

  ➤ Do not set down unevenly. 2. Set the machine down slowly and carefully. 12.2.5 Option rw Transport with a forklift truck Precondition The machine is shut down. All connecting lines and hoses disconnected and removed. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 254: Transporting The Machine As Load

  Packing and securing methods must be such that, assuming proper handling, the goods arrive in perfect condition at the destination. Additional measures must be taken for the transport of machines by sea or air. Please contact KAESER SERVICE for more information. Material Chocks…

• Page 255: Storage

  3. The loads must be secured against rolling, tipping, slipping and falling. Contact KAESER Service with any questions regarding transporting or load securing. KAESER accepts no liability and provides no guarantee for damage arising from incorrect transport or insufficient or incorrect load securing provisions.

• Page 256: Disposal

  Decommissioning, Storage and Transport 12.4 Disposal Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. Moisture and frost can damage the machine! ➤ Prevent ingress of moisture and formation of condensation. ➤ Maintain a storage temperature of >32 °F.

• Page 257: 13 Annex

  Fig. 108 Identification Machine nameplate with serial number Options label VIN* (stamped in the bodywork) Engine nameplate with serial number *Vehicle Identification Number 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 258
  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 262
  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 263: Dimensional Drawings

  Dimensional drawings 13.3.1 Option rb/rm/rs Dimensional drawing, chassis options ■ Option rb — Chassis EU version ■ Option rm — Chassis with height-adjustable towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 264
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 265: Dimensional Drawing, Chassis Options

  13.3.2 Option rc/ro/rs Dimensional drawing, chassis options ■ Option rc — Chassis GB version ■ Option ro — Chassis with fixed height towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 266
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 267: Dimensional Drawing, Chassis Options

  13.3.3 Option rd/ro/rs Dimensional drawing, chassis options ■ Option rd — Chassis USA version ■ Option ro — Chassis with fixed height towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 268
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 269: Dimensional Drawing, Chassis Options

  Option rb — Chassis EU version ■ Option rl — Chassis with higher axle load ■ Option rm — Chassis with height-adjustable towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 270
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 271: Dimensional Drawing, Stationary Version

  Annex 13.3 Dimensional drawings 13.3.5 Option rw Dimensional drawing, stationary version ■ Option rw — Skid frame on runners Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 272
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 273: Dimensional Drawing, Stationary Version

  Annex 13.3 Dimensional drawings 13.3.6 Option rx Dimensional drawing, stationary version ■ Option rx — On frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 274
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 275: Wiring Diagrams

  Annex 13.4 Wiring diagrams 13.4 Wiring diagrams 13.4.1 Electrical Diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 289: Lighting And Signaling System Connection

  Annex 13.4 Wiring diagrams 13.4.2 Option tc Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 297: Lighting And Signaling System Connection

  Annex 13.4 Wiring diagrams 13.4.3 Option te Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 302: Generator Electrical Diagram, 400V, 3-Ph

  Annex 13.4 Wiring diagrams 13.4.4 Option ga Generator electrical diagram, 400V, 3-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 311: Generator Electrical Diagram, 230V, 3-Ph

  Annex 13.4 Wiring diagrams 13.4.5 Option ga Generator electrical diagram, 230V, 3-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 320: Generator Electrical Diagram, 115 V, 2-Ph

  Annex 13.4 Wiring diagrams 13.4.6 Option ga Generator electrical diagram, 115 V, 2-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 329: Generator Electrical Diagram, 230 V, 2-Ph

  Annex 13.4 Wiring diagrams 13.4.7 Option ga Generator electrical diagram, 230 V, 2-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 338: Fuel Circulation Diagram

  Annex 13.5 Fuel circulation diagram 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 339
  Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 340
  Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 341: Assembly Diagrams — Chassis

  Annex 13.6 Assembly diagrams — chassis 13.6 Assembly diagrams — chassis 13.6.1 Assembly diagrams — chassis EU version Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 342
  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 343: Assembly Diagrams — Chassis Gb/Us Version

  Annex 13.6 Assembly diagrams — chassis 13.6.2 Assembly diagrams — chassis GB/US version Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 346: Assembly Diagram Brake Rod

  Annex 13.6 Assembly diagrams — chassis 13.6.3 Assembly diagram brake rod Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 347
  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 348: Operating Instructions For Compressed Air Filter (Combination Filter)

  Annex 13.7 Operating instructions for compressed air filter (combination filter) 13.7 Option dd Operating instructions for compressed air filter (combination filter) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 349
  FA (D), FB (D&E), FC (D&E), FD (E), FE (D&E), FF (D&E), FG STANDARD D-Pack D-PACK E-PACK Basic (OPTION) (OPTION) (OPTION) Kaeser Kompressoren GmbH Postfach 2143 96410 Coburg Tel.: 09561/640-0 Fax: 09561/640130 http://www.kaeser.com , 2 . 3 . 9 n u t…
• Page 350
  E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 2 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 351
  E-Pack: Filter mit Filtermonitor E-Pack: Filter with filtermonitor Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 3 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 352
  E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 4 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 353
  E-pack: Filter series FF with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 5 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 354
  We reserve the right to alter the specifications without prior notice Technische Änderungen vorbehalten. — 6 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 355
  Ausführende Tätigkeit. Changes sequence of operation Vom Bediener auszuführende Bedienschritte. 1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the filter — 7 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 356
  ∗ Es besitzt als solches eine zur Inbetriebnahme und War- tung derartiger Einrichtungen befähigende Ausbildung bzw. Berechtigung. — 8 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 357
  Filter/ -systeme zur Aufbereitung von Atemluft dürfen nur nach approved from manufacturer. Genehmigung des Herstellers der Filter/ -systeme eingesetzt und betrieben werden. — 9 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 358
  Annex 13.7 Operating instructions for compressed air filter (combination filter) 3. Technical data 3. Technische Daten — 10 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 359
  The coalesced liquids then drain to the bottom of Coalescings ausgefiltert. Die Luft tritt durch den perforierten äuße- the cartridge for removal. ren Stützmantel aus. — 13 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 360
  Filters und tropfen dann in den Filterbehälter ab. downstream to the bottom of the sleeve and drain to the bottom of the filter bowl. — 15 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 361
  Bei den Filtern FD, FG entfällt der Kondensatableitungsanschluß. Condensate drain does not exist in filters FD, FG. — 21 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 362
  Close the shut-off device in the bypass (if installed). Das Filter/ -system ist nun in BETRIEB. The filter/ -system is now OPERATIVE. — 24 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 363
  (Siehe Kapitel 9) The FG filter does not require a differential pressure gauge. Das Filter FG benötigt keine Differenzdruckanzeige. — 25 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 364
  F r e t i t a Bh = Kompressor-Betriebsstunden / Working hours — 32 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 365
  The filter(s) contain(s) systems under high pressure. hende Systeme. Alle pressure must be let off before servicing Vor Servicearbeiten sind sie drucklos zu machen. — 33 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 366
  Place filter under pressure again by slowly opening the Filter durch langsames Öffnen der Absperrvorrichtungen shut-off device. wieder mit Druck beaufschlagen. — 34 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 367
  ß i s l i Nähere Informationen finden Sie auch im Anhang ECO DRAIN. For more details please see annexe ECO DRAIN. — 35 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 368
  Personen unsachgemäß geöffnet oder repariert wurde und/oder mechanische Beschädigungen irgendwelcher Art aufweist. — 36 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 369: Operating Instructions For Compressed Air Filter (Fresh Air Filter)

  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) 13.8 Option dc Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 370
  ALYVOS GARŲ IR KVAPO ŠALINIMO FILTRAI ФИЛЬТРЫ ДЛЯ УСТРАНЕНИЯ ЗАПАХА И ПАРОВ МАСЛА FILTRI ZA ODSTRANJEVANJE OLJNIH HLAPOV IN VONJAV YAĞ BUHARI VE KOKUSU GİDERİCİ FİLTRELER FILTRI LI JNE{{U L-FWAR TA}-}JUT U L-IRWEJJA{ FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 371
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 372
  Указывает на требования по уничтожению использованных деталей и отходов • Označuje zahteve za odlaganje rabljenih delov in odpadkov. • Kullanılmış parçaların ve atıkların atılmasına ilişkin gereklilikleri vurgular • Tissottolinea l-kundizzjonijiet biex wie[ed jarmi l-partijiet u]ati u l-iskart FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 373
  • Įsitikinkite, kad naudojamas reikiamas įrankis • Убедитесь, что используется правильный инструмент • Poskrbite, da boste uporabili ustrezno orodje • Doğru alet kullanılmasını sağlayın • Kun ]gur li tintu]a l-g[odda t-tajba FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 374
  A instalação e a manutenção deste produto só deve ser realizada por pessoal autorizado e competente, sob estrita observância destas instruções de utilização e de quaisquer normas e requisitos legais relevantes, quando adequado. Conserve este guia do utilizador para referência futura FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 375
  I huma ffittjati b’indikatur tal-volum ta]-]ejt. Kemm l-elementi tal-filtru kif ukoll l-indikatur g[andhom jinbidlu jekk l- indikatur isir ta’ kulur blu. Jekk Jog[;bok Innota — Dan hu indikatur tal-volum ta]-]ejt u ma jindikax i]-]mien li jdum iservi l-element tal-filtru. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 376
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 1/4” 1/2” FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 377
  020 C 020 D 020AA 020AC 020 E 025AA 025DAC 025 D 025AA 025EAC 025 E 030 E BOIE1 AC010 I — AC030 030AA 030AC 030 F 030 G FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 378
  I sono provvisti di un indicatore degli oli misti. Sostituire gli elementi filtranti e l’indicatore quando il secondo assume una colorazione blu. Nota — L’indicatore segnala la presenza di oli misti, ma non la durata dell’elemento filtrante. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 379
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 0 bar 0 bar 0 psi 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 380
  13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 0 bar 0 psi 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 381
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 382
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 383: Service Tasks — Generator

  In order to ensure a safe operation of the machine, the generator must be inspected once every year by a trained and authorized electrician. Have the following tasks performed by a specialist electrician or an authorized KAESER service representative: ■…

• Page 384
  Annex 13.9 Service tasks — Generator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

 ‘BS 50/60 501.170
BS 50
BS 60
KAESER COMPRESSORS, INC. 911 Sigma Drive e P.O Box 946 ® Fredericksburg, Virginia 22404
| Tel. (540) 898-5500 e Fax. (540) 898-5520
ma
IMPORTANT
Read entire service manual before operating
unit or performing any maintenance.
Always shut off power to unit at main dis-
connect switch before attempting any main-
tenance. All system pressure should be dis-
charged unless manual instructs otherwise.
Use only 'Kaeser Compressors' approved
replacement parts.
Compressed air from any oil lubricated Kaeser
compressor is not suitable for use in any
breathing apparatus or food related process.
(Food grade oils are available on request)
ATTENTION
IKKaeser Compressors declines responsibility
for any modifications made to any Kaeser
compressor other than those made at the
Kaeser factory or those made with prior
written permission from Kaeser Compressors,
RTE
BS/CS 3-06.85
> Dv NN =
. Dimensions and specifications
. Description of the SIGMA screw compressor
. Design and function of the unit
. Installation
4.1 Ventilation of the air-cooled units
4.2 Air discharge connection
4.3 Electrical connection
4.4 Overload relay adjustment
. Preparation for initial start-up
5.1 Malfunction, KAESER CONTROL
5.2 Idle time adjustment
5.3 Pressure switch adjustment
. Maintenance schedule
6.1 Air inlet filter
6.2 Filter mat
6.3 Oil filter
6.4 Oil separator
6.4.1 Filter replacement
6.4.2 Mounting of the elastic pipe connection
6.5 Compressor oil specification
6.5.1 Adding oil
6.5.2 Oil change
6.5.3 Synthetic oils
6.6 Temperature gauge and high temperature switch
6.7 Motor lubrication
6.8 V-belt tension
6.8.1 V-belt changing
6.9 Checking the cooler
6.10 Spare parts list
6.11 Maintenance check list
. Wiring diagram
8. Checking the safety valve at the oil-air sump
10.
11.
12.
13
Automatic condensate drain
Dimensional drawing BS
Dimensional drawing CS
Transportation instructions
Conversion instructions for Screw Compressors Model BS/CS
from soundproofed to super soundproofed design
KAESER
COMPRESSORS
21/14
23
24
25
26
27
KAESER
COMPRESSORS:
1. DIMENSIONS AND SPECIFICA TIONS
BS/CS 3 - 09.82
Model Maximum Free air, delivery Motor | Dimensions
ode pressure uni inches
psig cfm kW hp length - width - height
Г BS 44 110 170
BS 44 145 155 30 40
BS 44 190 135
BS 50 110 195
BS 50 145 165 30 40 62 x 40 1/4 x 52 3/4
BS 50 190 145
BS 60 110 240
BS 60 145 205 37 50
BS 60 190 178
CS 75 110 282
CS 75 145 252 45 60
CS 75 190 215
CS 90 110 345
CS 90 145 300 55 75 70 1/2x 44 1/2 x 56 3/4
CS 90 190 260
CS 120 110 458
CS 120 145 390 75 100
CS 120 | 190 340
2. DESCRIPTION OF THE SIGMA SCREW COMPRESSOR
The main components of the Sigma Screw Compressor consist of housing and two rotors.
The compressor operates according to the rotary piston principle and is driven by an
electromotor through V-belts.
intake main shaft
J male rotor X
|
dM m
EE
==> discharge
discharge
Om lit»
o male rotor female rotor oil injection °
Figure 1
There are two rotors with antifriction bearings in the housing: a male rotor with 5 lobes
driven by the motor and a female rotor with 6 voids. While the rotors are turning, air is
drawn in through the inlet port at the upper side of the housing and the trapped air is
compressed at the lower side.
The oil injected into the housing at the lower side absorbs the heat produced by the
compression process, prevents the rotors from coming into contact and lubricates the
antifriction bearings.
As there are no unbalanced forces, inlet or outlet valves, smooth running of the unit
is ensured.
BS/CS 3 - 09.82
MAESER
COMPRESSORS
3. DESIGN AND FUNCTION OF THE UNIT
Figure 2
& air ling
(7) minimum pressure
check valve
= discharge vale
shutoff valve $C Ts 17 9
12) thermostatic valve
00) differential pressure switch
11) micro oil filter
vacuum switch
— differential
$ 27) pressure
switch
ait
TU
У sef
6 e
«7 (Q pressure
à > | be gauge
| и ЛАЙ
(8) air-cooled connecting tube D “o O cil level
aftercooler E temperature indicators
| <. = gauge
compressed air Oi ling в
outlet pressure
switch
22) excessive temperature switch
(3) check valve combined
(9) pressure gauge © oil-air sump,
AIR FLOW
© Air inlet filter
Cleans intake air
© Screw compressor
©
©
@ ©
BS/CS 3 - 09,82
©
©
©
The air is compressed, The heat
produced by compression is ab-
sorbed by the oil,
Check valve
Prevents the backfiow of oii-
alr mixture
Connecting tubo
with elastic pipe connection
Combined oil-air. sump
Sarves as oil storage sump and for
first stage of oil/air separation
Cil separating cartridge
Separates the oil from comprossed
air
Minimum pressure check valve
Safeguards compressor lubrication
by maintaining minimum pressure
within oil sump fer adequate
huorication at all times
Air-cooled aftercoolor
The compressed air is cooled almost
to ambient ltamperatura
Compressad ais outlat
&Lir pressure can be taken from a
" threaded or flanged connection
OIL CIRCULATION
o
®
Combined oil-oir sump
Separates oil trom compressed
air and diracts tho oil back to
circulation
Micro oil filter
Cleans tha total oil flow through
a fino replaceable cil cartridge
Thermostatic valve
Controls the oil temperature and
thus prevents moisture separation
in the compresses air and in the
ail.
Result: cold oi! is directed back
to the compressor ~
warm oil closes this
passage and is then directed
to the oil cooler
Ой cooler (air-cooled)
Cools the heated oil
Oil stop valve (deenergized closed)
Opens the passage far oil injection
after the compressor has been
started and closes it when the
compressor has been stopped
Qi} return line with narzle
Directs the oil, separated in the
oil separator, back to the inlet
side of the compressor
CONTROL
(9)
©
Intel vale
Opens at full load and closes when
the compressor is idling or stopped.
The inlet valve is controlled by the
cnntrol valve,
Discharge valve
Ventilates the oil-air sump when
the compressor is idling or stopped,
Result: low idling power,
loadless starting
This valve is pneumatically controlled
by the control valve.
Pressure switch
Controls the compressofr between
full load and idling time
TITI
COMPRESSORS
SAFETY CHAIN
© © O © ©
© © ©
Pressure gauge
Indicates the pressure at discharge
Safaty vale
Protects the oil-air sump against
exceeding the maximum pressure
Temperature gauge
Indicates the final compression
temperature at the airend
Excessive temperature switch
Cuts out the compressor at excessivo
temperature (212°F measured at the
alrend)
Oil stop valve (deenergized closed)
Regulates oil flow into compressor
and thus eliminates excessive load
on the motor
Oil level indicators
Maximum and minimum oil levels
can be cnecked through two sight
glasses
Control valve (deenargizod closed)
Supplies pressure to the control
cytindar of the inlet valve and
discharge valve or ventilates them.
The control vaive is controlled by
the pressure switch 18,
Pressure switch
Shuts down the unit if the Y -belts
ara broken, if the direction of
rotation is wrong or if the unit is
operating on one phase only
Differential pressure switch
indicates the contamination of the
oil separating cartridge
Differential pressure switch
indicates the contamination of the
oit filter
Vacuum switch
Indicates the contamination of the
intake filter
BS/CS 3 - 09.82
4. INSTALLATION
4.1 Ventilation for air-cooled units
KAESER
COMPRESSORS
Installation of the screw compressor should take place according to the following schedule.
For easy access and service, respect the minimum distances indicated below.
Figure 3
Possibility
BS
5
В:
>
air outlet duct
SN
IU ete
И
г
LA
A
LA
bl
г
г
и
#
Je
1
Possibility
B
_. >
Passibility A «a
ty — a
== =
= = 6 ;
— =f =
J LA
| . NN d ©
32 | 62 1 a
gt + y
LA
LA
| 1
FA Ap AF FE EE
АВ
180
H
dl ИРА
A 4
ZA fan "|
+ Г
+ + 9
++“ Possibility A ; o
A NN
LA
+ R A
| -— > inet air
— — NN Hentrance
— — u
== = 5]
air discharge connection 1 1/2. NPT
 electrical connection
CS
Possibility [| Possibility A & |
B = = si 1
> = == <=
} = o o «tr a
y PY] A o
A. j PL ` { A «Y
4 32 F” 70 1/2 1 / -
и и
A и
и Г Y
ИИ РОС
+ и
L 48
180 _
A y
NN AN AA EET AEE EE
=
2
и di
| ; A, fan. Г
я wn mgm У
1 *<> Possibility A / o
J a
air outlet ducti- rr RB CT
=1 °F 1 = A.
с — - = Alnlet air
= . — © dentrance
P » de + I LS i © я м > {
ossibility o  electrical connection
B x |
air discharge connection 2 NPT
The compressor room should provide adequate ventilation.
Dimensions. in inches
Possibility A Possibility B Required size at
Mode! Ventilation: fan Exhaust air is air inlet entrance
cfm at a static pressure used for heating for A and B
of 0.4 inches WC w x h inches sq. ft. »
——
BS 44 5000 27 x 30 6.5
BS 50 5000 27 x 30 6.5
BS 60 6200 27 x 30 8
CS 75 —- 7700 36 x 34 10
CS 90 9500 36 x 34 13
CS 120 14000 38 x 40 17.5
BS/CS 3-06.85
KAESER
ESSE
Possibility A:
Air delivery of the exhaust fan must be adequate for the size of the unit (see chart on
page 5).
Possibility B:
Warm exhaust air is forced through a duct into the room to be heated. Consult KAESER
COMPRESSORS for maximum allowable pressure drop in exhaust ducts.
To ensure trouble-free operation of the unit, cooling air temperature shoutd not drop
below 40°F and not exceed 100°F.
4.2 Air discharge connection
The unit is piped ready for operation. It must be connected to the air line with a
flexible connecting hose. A check valve is not required in the discharge line as one is
built into the unit. '
4.3 Electrical connection
The unit is wired ready for operation and it needs only be connected to the supply line.
Pull the cable with conductors L1, L2, L3 and earth E through the openings of the base
frame into the controller and connect them to the terminals marked L1, L2, L3 and
earth E. The main disconnect switch and main fuses must be supplied by the purchaser.
This main disconnect switch must have a minimum switching capacity which is 1.1 times
the indicated rated power of motor.
The required fuses and cross sections of cables are shown in the following chart.
WYE-Delta start WYE-Delta start
230V, 3-phase, 60 cycles 460V, 3-phase, 60 cycles
Model Motor Fuse dual Conductor Fuse dual Conductor
element wire size element wire size
kW hp Amps AWG Amps AWG
BS 44 30 40 100 1 60 |
BS 50 30 40 100 1 60
BS 60 37 50 150 1/0 80
CS 75 45 60 200 3/0 100 3
CS 90 55 75 225 4/0 125 2
CS 120 75 100 300 350 MCM 150 2/0
KAESER
COMPRESSORS
4.4 Overload relay adjustment
WYE-Delta start 460 V, windings WYE-Delta switching.
Only the phase current of a winding is led through the overload relay. This phase current
is only 0.58 time the motor rated current NE accordingly the relay has to be adjusted
for IN x 0.58,
Adjustment:
~ The overload relay should be adjusted approx. 10 % higher than phase current of a winding.
BS/CS 3 -04.84
This will prevent it from acting at voltage fluctuations.
5. PREPARATION FOR INITIAL START-UP
Every Screw Compressor is operated and thoroughly tested at the factory before shipment
to make sure the compressor delivers its rated capacity and is in good working order.
However, all the care given at the factory will not prevent possible. damage during transit.
We recommend the unit be carefully inspected for evidence of possible damage in shipment.
During the first few hours of operation, the machine should be watched for any possible
malfunction.
Comply with the following recommendations before initial start-up
® Do not operate the compressor at a voltage other than the one specified on the
compressor nameplate.
® Do not operate the compressor at pressures exceeding the maximum pressures
indicated on nameplate.
e Install the compressor in an area where the air inlet temperature is at least 40°F
but no higher than 100°F.
e If an air outlet duct is provided, it should be at least the size of the cooler surface
and its length should not exceed 13 ft. ;
® Install the compressor to maintain a distance of 2 ft. between the cooling air inlet
of the unit and the wali.
® Check for proper direction of rotation.
® Make sure the shutoff valve (figure 22) is open.
e Shut off the unit, tighten up all the screws in the control box (repeat this after
50 operation hours).
e Make sure the maintenance doors are closed.
BS/CS 3-06.85
"COMPRESSORS.
Start-up after oil change and/or long standstill
The following procedure must be observed when starting the unit after an oil change
and/or a standstill period of three (3) months and over.
To add oil in the airend intake port:
Before starting the unit, pour oil in the airend intake port, in quantites below
recommended and rotate the airend by hand.
Model Quantity
BS 44 1 pint
BS 50/60 1 quart
CS 1 quart
Important:
Use the same brand and quality of oil as the one being used to operate the compressor
unit only (refer to the specs label on the oil separator tank), or drain oil from the
oil! separator tank and use for that purpose.
Caution:
Discharge pressure in unit before draining any oil.
To add oil, unscrew the air inlet connection at the inlet port, open the butterfly valve
by hand and pour recommended amount oil into the airend. Screw air inlet connection
back on.
To increase Wye time at start-up
For start-up, increase Wye-Delta time relay to 30 seconds to prevent compression of
inlet air during start-up. Stop unit by pushing stop button JUST BEFORE REACHING THE
30 SECOND LIMIT, | :
Once this is done, the Wye-Delta time relay must be set back to its normal operating
point according to the following chart.
Model WYE time
BS 9 sec.
CS 75/90 9 sec.
CS 120 12 sec. .
These two preventive measures will ensure that the airend is getting sufficient oil when
starting up the unit and will provide sufficient time for filling the oil cooler and all
oil lines,
7a
BS/CS 3 - 09.82
Checking the direction of rotation:
MAESER
COMPRESSORS
- Push momentarily start and then stop button (parts 6 and 7, figure 4) and check for
proper direction of rotation.
- Arrows on motor and airend housing indicate direction of rotation.
- Should direction of rotation be incorrect, conductors L1 and L2 must be interchanged.
Important:
If the compressor rotation is wrong, pressure switch No. 26 (figure 2) will automatically
shut compressor off.
Compressor start-up
- Cut in main disconnect
switch
- Push start button
(part 6, figure 4)
Compressor stop
- Push stop button
(part 7, figure 4)
- Shut off main disconnect
switch
Important:
Do not shut off the compressor
operating with load at the
main disconnect switch,
“= O
instrument Panel
OO
000008 ©
© 0
О 2 3 4 5 8 6 7
Figure 4
Outlet pressure of unit O
Temperature gauge
Hourmeter (service hours)
Hourmeter (full load hours)
KAESER CONTROL
Start button
Stop button
Reset button
O 4 TA WN-
BS /CS 3 - 09.82
MAESER
. COMPRESSORS.
5.1 Matfunction
Safety system: KAESER CONTROL
KAESER CONTROL
O reset button
Overload of motor (overload relay)
Excessive temperature
Airend - low pressure
Oil filter contamination
Oil separator contamination
Air inlet filter contamination
| shut down
functions
DS A (2 ГО —
| indicating
lights
O CODO
Figure 5
In case of malfunction (lights 1, 2 or 3) the compressor is shut down by:
1 Overload relay of the motor.
After having eliminated the trouble, push first the contact pin at the overload relay,
then the reset button (figure 5). Now the compressor is ready for operation.
2 Thermostatic switch for final compression temperature will shut unit off when temper- |
ature reaches 212" F.
3 Pressure switch (No. 26, figure 2) at the air outlet port of the airend will shut down
the unit if the direction of rotation is incorrect or the V-belts are broken or have
slipped. This pressure switch is jumped during the WYE-time.
Maintenance requirements are monitored by indicating lights 4, 5 and 6 with warning
functions only.
. 4 Differential pressure switch (No. 28, figure 2) indicates oil filter contamination.
5 Differential pressure switch (No. 27, figure 2) indicates oil separator contamination.
6 Vacuum switch (No. 29, figure 2) indicates air inlet filter contamination.
Watch and check indicating lights 4 and 5 after unit has been running for a minimum of
5 to 10 minutes from start-up. Warning light 6 will stay on until cartridge is cleaned.
+
During any one of the above malfunctions, the reset button red light will come on.
To restart unit, press reset and "ON" buttons.
To check whether the warning lights are working, press reset button. All lights should
come on.
BS/CS 3-06.85
KAESER
COMPRESSORS
52 Idle time adjustment
The time delay relay for idling time is located in the control box {time 0.5-10 minutes).
The idling phase should be set in such a way that the maximum permissible cutting
in frequency of the motor is not exceeded.
Cutting in frequency (per h) | Cutting in frequency (per h)
Model IP 23 IP 44 Mode! P23 | IP 44
_ ae
BS 44 15 8 CS 75 15 15
BS 50 30 15 CS 90 15 8
BS 60 15 15 | CS 120 8 8
5.3 Pressure switch adjustment — Adjustment of the switch differential at the
= | pressure switch for limiting the switching
B 420 at 110 psig max, pressure frequency.
| 100 E Maximum frequency of idling operation:
E twice a minute O
2 $ |
2 © By increasing the switch differential between
9 - cut-out and cut-in the switching frequency
с о can be reduced to a limited extent. If this is
7 е not sufficient a larger air tank is required.
3 ls
> eo 5% e» W Y The pressure switch has been pre-set at the
cut-out pressure -—e= psig factory as follows:
co
a at 145 psig max. pressure 110 psig units: 100 to 110 psig (Ap = 10 psi)
= 145 psig units: 135 to 145 psig (Ap = 10 psi)
| Е 190 psig units: 180 to 190 psig (Ap = 10 psi)
o 3 Pressure adjustment can only be carried out
2 = at the mounted pressure switch when the air
$ = tank is under pressure.
&
D
= o Cut-out pressure:
a. | Ta
Q
Mw 10 180 For higher pressure: turn handwheel to the gioht
cut-out pressure -——e= psig for lower presssure: turn handwheel to the t
св
Z ¿At 190 psig max. pressure ‚ Cut-in pressure/switch differential:
E
| 10 Е To increase the difference between cut-in and
5 cut-out pressure:
o 5
> = - remove locking pin |
o © - press handwheel so that the cross pin at
a ©, the top of the handwheel comes out,
= m then turn handwheel to the left
3 - place in locking pin.
VO 20 140 160 180 200 220 240 . ,
cut-out pressure —= psig To decrease the difference between cut-in and
cut-out pressure:
- remove locking pin
locking pin - proceed as indicated above but turn hand-
handwheel wheel to the right
| - place in locking pin
pressure switch Caution
Before removing the pressure switch cover,
shut off the compressor (stop button and main
disconnect switch). After each readjustment at
pressure switch, place cover on pressure switch
Cinurae A _ Q before switching on the compressor. 10
BS/CS 3 - 09,82
6. MAINTENANCE SCHEDULE
Always follow maintenance instructions:
MKAESER
COMPRESSORS
- Before performing any maintenance on the unit, cut off main disconnect switch to make
sure the power is off.
- Before restarting, make sure no one is working on the unit and covering plates are
back on.
- After switching on main disconnect switch, start unit by pushing start button.
- In case of power failure or cutoff at main disconnect switch, restart unit manually by
pushing the start button.
- The socket to vent the tank is placed in a plastic bag inside the control box. It is used
for maintenance work, such as oil refill, oil and filter change.
6.1 Air inlet filter
Clean the air inlet filter, when the warning light 6 of KAESER CONTROL (figure 5)
comes on.
e
LL
+?
air inlet filter cartridge
cyclone guide vanes
Figure 10
Figure 12
Shut off the compressor (stop button and main
disconnect switch).
Opening of the filter housing (figure 10):
Remove and empty dust container.
Important: Make sure dust container is
reassembled correctly.
Cleaning by tapping off the dust (figure 11):
Tap the front side of the cartridge against
your palm until all the dust has fallen out.
Avoid damaging the cartridge. Clean the
contact surfaces of the gaskets.
Blow clean with compressed air (figure 12):
Blow dry compressed air (no higher than
70 psig) slanted against the paper pleats.
Then blow clean the inside of the cartridge
thoroughly.
Cleaning by rinsing (in case of oily dust):
Add industrial solvent to lukewarm water and
agitate cartridge. Rinse thoroughly in clean
water, shake and dry (figure 13). Never use
gasoline, lye solutions or hot fluids.
Replace cartridge after several cleanings or
if cartridge is overly contaminated.
14
BS /CS 3 - 09.82
6.2 Filter mat
HAESER
‘COMPRESSORS
Clean filter mat every 100 to 300 operating hours depending on amount of dust.
Figure 14
6.3 Oil filter
- Shut off the compressor {stop button and main
disconnect switch).
- Remove cover frame with a screwdriver.
To mount, turn screws 90° (figure 14).
Cleaning:
Rinse the mat in water of approx. 100°F
with some fine washing detergent. Cleaning
can also be done by tapping, vacuuming, or
blowing the dust off with compressed air.
With oily dust, rinse the mat in safety solven'Q
or warm water.
- If mat is excessively soiled, replace.
Replace the oil filter after the first 100 to 200 hours (depending on environment), there-
after every 2000 to 3000 service hours, or when warning light 4 of KAESER CONTROL
comes on.
Figure 18
Shut off the compressor (stop button and main
disconnect switch).
Place vent socket into hose coupling (1, figure.es:)
at the tank (the tank loses its pressure).
Then wait about 1 minute until the oil settles.
Unscrew clogged filter by turning the filter
counterclockwise and discard.
Clean sealing surface at the filter head
thoroughly with lint-free cloth.
Lubricate the filter gasket lightly with oil.
Screw in the new filter manually until the
cartridge gasket fits tightly. Do not use any
tools! Pour oil into the sump to normal level. ‚
Important:
Remove vent socket from hose coupling. Start up
the compressor and check for leakage.
19
6.4 Oil separator
Fe o
If the cartridge is contaminated (indicated by warning light 5 of KAESER CONTROL),
replace. Start by pressing start button. The unit is ready for operation.
6.4.1
Figure 19
Filter replacement
Shut off the comsressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Place vent socket into hose coupling at the
tank (the tank loses its pressure), see 6.5.1.
- Loosen self-locking nuts 5 and 6 of the elastic
pipe connection and remove bracket halves.
- Loosen pipe fittings (1), remove screws (3)
and sump head (4).
- When changing the cil separating cartridge,
unscrew and replace screen filter (7). This
filter is mounted on the oil return line at
the sump head.
- Replace the two gaskets (D). All the afore-
mentioned components come with the spare
oil separating cartridge.
- Assembie parts in reverse order.
- To install elastic pipe connection, please
refer to 6.4.2.
- Remove the vent socket.
642 Mounting of the elastic pipe connection
1 b Figure 20
od Model $ Order No.
co |
5 B3 44 2 21/32 (2.66)| 5.1390.0
с BS 332 (322)| 519910
Ú CS 3 2932 (3.72) 5.1392.0
^^
o Dimensions in inches
- Cutting edge "a" of pipe 1 has to be
burr-free and surface "b" clean.
- Place cone ring holder 3 and cone ring 2
on pipe 1.
- Place pipe 1 into sleeve 7 without preliminary
stress; push cone ring 2 with cone ring holder 3
up to the cone end of sleeve 7 (realign the
pipe, if necessary).
- Расе the bracket halves 4 on the cone ring
holder and sleeve and tighten according to
measurement ''5''.
Measurement "s" is a recommended value
and can fluctuate by approx. 2 %.
- Tighten locking screws so as to allow adjusting
by hand when the unit is off. When the unit
is operating at full load, all screws must be
under equal load.
After the seif-locking nuts 5 and 6 have been
tightened and loosened several times they have
to be replaced,
BS/CS 3-02.85
6.5 Compressor oil specifications
Er
ENERGOL THB 46
ENERGOL HLP 46
=
HYSPIN AWS 46
Ho
Chevro
=
OC TURBINE OIL 46
CALTEX REGAL ОШ
R+0
| EXXON
—
|
NUTO H 46
Mobil
D.T.E OIL MEDIUM
ROTELLA 10 w*
X 100 Motoroil 10 W
Shell
(ТЕХАСО) RANDO OIL HD 46
02.25.85
6.5.1 Adding of oil
—il
KAESER
COMPRESSORS
The oil used for cooling the screw compressor
during operation must have the following properties:
- high aging resistance
- high dispersive power
- low emulsifiability
- minimum capacity for forming foam
Basic oil: ~ solvent raffinate
Hydraulic or turbine oil: viscosity class VG 46
Viscosity at 104°F: approx. 42-50 cSt
(200-230 SU sec)
Flash point, surface
temperature:
Pour point:
above 392°F
at least 18°F below owl)
ambient temperature
To ensure trouble-free operation, use only one
of the oil types listed on the left. These oil
types are of comparable quality and can be
purchased from the listed oil: companies or
service stations.
The order in which the oils are listed is not
indicative of or related to the quality of the
oils.
‘The oil companies reserve the right to change the
names of the oil designations!
“The oil sort "Rotella X 10 W" is mixable with
the filled in oil sort "Shell comptella oil 46"
respectively "Shell oil S. 9159"
Check oil level daily at the oil sight glass.
Always shut compressor off when checking, .
the oil. Oil must be added when the minimum
oil level, which is the middle of the lower
oil sight glass, has been reached. Fill to the
middie of the upper oil sight glass, no higher.
DO NOT OVERFILL.
- Shut off the compressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Place vent socket (1) into coupling (2) at the «+
tank (the tank loses its pressure).
- Loosen locking screw (5) at the filling vent.
- Pour oil in to the max. level.
- Check gasket and tighten locking screw (5).
- Remove vent socket (1) from coupling.
important:
Always use the same make and type of oil.
(indicated on the oil-air sump)
14
652. Oil change
KAESER
ERTIES
The oil must be changed approx. every 2000 to 3000 service hours depending on contam-
ination of inlet air.
If the unit operates at or close to ambient temperature of 100°F (for example in boiler
rooms etc.) the oil must be changed more frequently, i.e. every 1000 - 1500 hours.
important: Drain all oil from the oil/air sump, cooler and lines.
O shutoff valve
BS/CS 3-10.84
Figure 22
important:
closed open
For restart procedure please refer
to instructions on page 7a.
Model
[a ——— —[]]" o Ba rer ar
BS
CS 75/90
CS 120
Oil charge
approx. 9 1/44 US Gal
approx. 16 US Gal
approx. 18 1/2 US Gal
=
Oil change with pressure produced by another
source:
Shut off the compressor (stop button and main
disconnect switch).
Open maintenance doors.
Close shutoff valve.
Hook hose (3, figure 21) of other pressure
source to socket (1, figure 21) onto tank
and pressure feed.
Remove hose with socket (the tank should
have a pressure of approx. 30 psig).
Slowly open tank drain valve (4, figure 21).
The pressure remaining in the tank will
cause the oil to flow.
After discharging air tank, slowly open the
cooler drain plug (the oil will drain without
pressure).
Close drain valve and drain plug.
Open shutoff valve.
Oil adding see item 6.5 and 6.5.1.
Oil change with pressure produced by the
compressor:
Shut off the compressor (stop button and main
disconnect switch).
Open maintenance doors.
Close shutoff valve.
Let compressor run for about half a minute.
Shut compressor off {stop button and main
disconnect switch).
Slowly open tank drain valve (4, figure 21).,
The pressure remaining in the tank will
cause the oil to flow.
After discharging air tank, slowly open the
cooler drain plug (the oil will drain without
pressure).
Close drain valve and drain plug.
Open shutoff valve at the tank cover.
Oil adding see item 6.5 and 6.5.1.
15
BS/CS 3-03.85
KAESER
COMPRESSORS
6.5.3 Synthetic Oils
The following synthetic oil brands have been approved for use in KAESER screw
compressors:
Manufacturer Brand Name
Nuodex Anderot 497
Keystone KSL 220
Also any other brand with the same specifications. Consult KAESER COMPRESSORS for
brands not listed.
Two important requirements are: | e
Viscosity at 175% F: 10-12 est
Foaming Test ASTM D 892-74: Sequenz II 20/0
Extra care must be taken when changing from mineral oil use to synthetic oil or
when changing oil brands, Make sure that all oil in the separator tank, oil lines,
oil cooler and airend has been drained.
When switching from mineral oil to a synthetic oil it is recommended that the
first change of synthetic oil be replaced after 100 h of operation, along with
the oil filter. This is because the synthetic oil will act as a solvent and remove
deposits left by the mineral oil. Once the compressor is free of deposits, follow the
recommended oil and filter change interval.
Also, when switching from mineral oil to a synthetic oil, the plant system materials
must be re-evaluated. Certain plastics are not compatible with synthetic oils.
The foliowing is a partial list of acceptable and not recommended materials:
Acceptable Not Recommended
Viton Neoprene
High Nitrile Buna N : SBR Rubber .
Teflon Low Nitrile Buna N
Epoxy Paint | Acrylic Paint
Oil-resistant Alkyd Lacquer
Nylon Polystyrene
Delrin PVC
Celcon ABS
Consult KAESER COMPRESSORS, INC. for details or materials not listed.
Caution: synthetic oils are not compatible with polycarbonate bowls. Any such
bowls in the compressed air system should be covered with metal bowl guards or
replaced with metal bowls.
15a
BS/CS 3-09.85
COMPRESSORS:
6.6 Temperature gauge and high temperature switch
When final compression temperature reaches 230° F, the compressor shuts off and warning
light 2 (excessive temperature) on the KAESER CONTROL (Figure 5) comes on.
Troubleshoot and repair.
Probable causes: malfunction in the cooling system, e.g.:
low oil level
extreme ambient temperature (toc low or too high)
clogged oil filter
clogged oil cooler
clogged filter mat
To restart, press reset (8) and start (6) buttons (Figure 4).
The compressor is back in operation,
6.7 Motor lubrication
Models BS 44 up to CS 90:
The standard motors have life-time grease lubrication.
Under normal working conditions (ambient temperaure 40° F), carry out maintenance
of the motor bearings according to the following chart.
After the indicated working hours, demount motor bearings, rinse them and fiil
the void spaces with new grease.
Model CS 120:
The standard motors are equipped with relubrication system.
Under normal working conditions (ambient temperature 40° F), carry out relubrication
of the motor bearings according to the following chart.
After the indicated working hours, relubracte motor bearings with the indicated
amount of grease.
Lubrication interval Amount of grease
Model ‘
operating hours ounce
BS 44 16 000 -
BS 50 32 000 -
BS 60 32 000 -
CS 75 32 000 -
CS 90 32 000 -
CS 120 8 000 3/4
We recommend the following brands of lithium base grease: BP Energrease LS 3
Calypsol H 443
Exxon Beacon 3 *
Mobitux Grease 3
Shell Alvania 3
SKF Waelzerol FL
Under harder working conditions, i.e. strongly poliuted intake air and ambient temperature
of the unit, approx. 105° F, lubrication interval is half as long.
For special motors, other protective systems etc., follow manufacturer's instructions
(on motor name plate).
16
BS/CS 3-06.85
6.8 V-belt tension
ULA
+ .
————
1 —
HF
2 —F
| range of automatic
a V-belt retensioning
min 4
max
|
3 A
==
Figure 23 |
6.8.1, V-belt changing
&
&
EE
NE
Y
Figure 24
HAESER
‘COMPRESSORS:
Belt tension must be checked every 500
operating hours.
The V-belt span is adjusted automatically
within a limited range by the pressure spring.
See figure at left,
An indicator pin 3 in the oblong hole indicates
the V-belt span. When the pin 3 reaches the
top of the hole, retensioning is required.
Shut off the compressor
main disconnect switch).
Loosen hex nut 1.
Retension the V-belt by
(stop button and
turning the hex
nut 2 until the pin 3 is all the way down.
Retighten hex nut 1.
Shut off the compressor (stop button and
main disconnect switch).
Open left maintenance door.
Unscrew and remove covering plate 0
from fan frame.
Place V-belt first over the free-
standing fan blade, then turn fan and
move belt over the other blades.
Turn adjusting hex nut (2, Figure 23)
at the swing support downwards.
Slip V-beit over motor and compressor
pulleys.
Tension V-belt. (see section 6.8.)
Fasten covering plate on
Close maintenance door.
the frame.
Check V-belt tension after approx. 2
and 24 operating hours.
Important:
Spare V-belts must be marked SPZ and be
100 % oil resistant.
17
18
the cooler out-
oC
O
2
)
Ш
ая
e.
=
Q
Q
|
Ml
left and the upper maintenance doors.
fins with compressed air from inside or spray
- Unscrew air pipes B and C, valve combination D
and contro! line E from the cooler.
Contamination of the cooler can be checked
through an inspection hole. lts location is
Check cooler at least every 1000 operating
- Remove covering plates A and open the
- If cooler is contaminated, blow clean cooling
- Reassemble parts in reverse order.
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6.10 Spare parts list
Maintenance parts
KAESER
COMPRESSORS .
Maximum V-belt Oil filter | Oil separation | Air inlet Filter
Model pressure cartridge cartridge filter mat
compl.set compl. set cartridge
psig pes.| Order No.| Order No.| Order No. Order No. Order No.
—_ NT ee?
110 4 6.2540.0
BS 44 145 4 6.2540.0 6.1981.0 6.2012.0 6.1996.0 6.1938.0
190 4 6.2540.0
110 6 614340 o
BS 50 145 6 6.2533.0 6.1981.0 6.2012.0 6.1996.0 6.1938.0
190 6 6.2542.0
110 6 6.2532.0
BS 60 - 145 6 6.1434.0 6.1981.0 6.2012.0 6.1996.0 6.1938.0
190 6 6.2533.0
110 9 6.1432.0
CS 75 145 9 6.2521.0 6.1981.0 6.2013.0 6.1997.0 6.1945.0
190 9 6.2522.0
110 9 6.2529.0 |
CS 90 145 9 6.1432.0 6.1981.0 6.2013.0 6.1997.0 6.1945.0
190 9 6.2521 .0
110 9 6.2529.0
CS 120 145 9 6.1432.0 6.1981.0 6.2013.0 6.1997.0 6.1945.0
190 9 6.1432.0
Hoses
Hose line Hose line
Model Vent line Oil stop valve
Order No. Order No. |
BS 8.0864.0 8.1139.0
CS 75/90 8.0806.0 8.1138.0
CS 120 8.0806.0 8.1100.0 *
When ordering spare parts always state compressor type, serial number and year of
manufacture which are stamped on the nameplate.
important:
Order KAESER genuine factory-tested replacement parts only !!
KAESER
COMPRESSORS.
6.11 Maintenance check list
Record hours of operation and check maintenance work performed.
Record values where indicated.
Filter $ Air o | VI
mat filter |= © sepa- Oil fill V-belts
car- | b| rating
Hours of tridge 15 5 car- Ш Date Signature
operation tridge ©.
© Ч o ©)
lege @ © 10|0|52 reia
Ll =O oO о м © O ly © о
с |9 |519 о ров |515 | ® |5 |5 | <
v a D Q a ©. ve a | @ + e
2 © с с
о Io © © © O 2 o. о © ©
BS /CS 3 - 09.82
KAESER
COMPRESSORS
7. Wiring diagram for BS,CS, St 501.170 Page 1
1M
mt |
TT
1M
|
L2!'T2
1M
HI
L3" ‘T3
Input voltage
460V 3Ph 60Cy
TS Li ZM
— > 16 Sh
"тт xi
— Hh
A L3 2M
o © 1) 6 =|
a = 3
Main disconnect switch and
fuses must be supplied 3M
by the purchaser al
Jf -
T2
21/1
7. Wiring diagram for BS,CS, St 501.170
11
12
13
14
15
16
$
20
22
24
25
Page 2
AT |
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A2
1
| 81
£3
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BR 56
‘COMPRESSORS;
KAESER CONTROL
2 | 14 | st | ss | sé | | A270
: 10 HOFP 15
—
11 HOS 16
on 208 3 2 Wee In
Чек В. 1
4 onc
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21/2
KAESER
COMPRESSORS
7. Wiring diagram for BS,CS, St 501.170 Page 3
Alan
FEED
123143
HHO
21/3
7. Wiring diagram for BS,CS, St 501.170
1M Motor starter {main contactor }
2M Motor starter [delta contactar )
3M Motor starter {wye contactor)
20L Overload relay for transformer
T Transformer
M Motor
APS Air pressure switch
CR1/2/3 Contral relay
1SV Solenoid valve (controls inlet valve /
discharge valve)
3SV Solenoid valve (oil stop)
TR1 Time delay relay (delay - off ]
TR2 Time delay relay (wye time)
1PB Push button “off”
2PB Push button * an”
G Indicating light (green, ready for operation )
IR Indicating light (red, off)
HM Hour meter
LHM Load hour meter
CE
Pa : Er
) Г
Lh
KLEE ES
Malfunction Indicators:
101. Overload retay for motor
hutdown
ETS Excessive temperature switch functions
SAPS Safely air pressure switch
il filte
HOFP High oil ilter pressure indicating
HOSP High oil separator pressure lights
HAFP High air filter pressure
20L |CR1|CR2)CR3 HRITR
WIRE DUCT
T
|230] 0 {2300 |
1M
2M 3M
10L
A : Terminals
L60V 3Ph 60Cy
21/4
BS/CS 3-06.85
KAESER
COMPRESSORS
8. CHECKING THE SAFETY VALVE AT THE OIL-AtR SEPARATOR
To check the set maximum operating limit and the blow-off capacity, the unit must be
operated at a final pressure higher than maximum setting of the pressure switch.
Maximum pressure Set maximum operating
of the unit pressure of the safety valve
110 psig Ш 130 psig )
145 psig 175 psig o
190 psig 210 psig
* except Model CS 120: 175 psig
In order to avoid readjustment of the pressure switch, carry out checking in the
following way:
- Shut off the compressor (stop button and main disconnect switch).
- Close the shut off cock at the discharge line (Figure 22).
- Close the shut off cock downstream of the unit.
- Start the compressor and let it switch over to idling.
- While the discharge line is being closed the pressure can easily be checked as
it is increased slowly up to the limit where the safety valve will react. O
- Shut off the compressor and proceed in the reversa order.
a
O Figu re 27
BS/CS 3 - 09.82
KAESER
COMPRESSORS::
9. AUTOMATIC CONDENSATE DRAIN (OPTIONAL)
The condensate collected in the air tank is drained automatically by a solenoid valve
at regular intervals.
The solenoid valve is controlled by a time delay relay with timers at which the opening
times of the solenoid valve can be preset from 0.4 to 10 seconds and the intervals from
1.5 to 30 minutes, depending on the amount of condensate.
| —
time delay relay
a
a!
ji
fy
rt te
solenoid valve
dirt trap
Install a dirt trap in front of the solenoid valve to catch larger dirt particles and thereby
ensuring the solenoid valve's proper operation. Clean the strainer of the dirt trap at regular
intervals.
Make sure the dirt trap and solenoid valve are properly installed in the direction of the
arrow.
Connect a hose to the solenoid valve for the condensate to reach the sump.
23
BS/CS 3-05.84
HAESER
COMPRESSORS.
10. DIMENSIONAL DRAWING BS- air cooled with soundproofing casing
Dimensions in inches
at

/ fi
be ~. i
Service access oe
18%
| Service access door
I
~
| N,
< | 
PSE |
| Control panel Control cabinet ‚34%
ede — « = ai T
Зи, 28% | Cooling 4 air inlet 1 rr
pe — lt | 710
: air outlet о lo <—
| <
of + D
E |
LH A 4 °H ï ¿
4. E e = À
т? | < я
J LJ 1 > LJ
6% 5 _ 54 Va | 5% _ "dia. 1716
32 1% ||_ 62 N Ву _ día. 17%:
LS Ce a — Openings
40% Air discharge diameter 1%: NPTM lor electrical
connection
+
24
BS/CS 3-05.84
Dimensions
in inches
Service access door
KAESER
Nolo VL IO
11. DIMENSIONAL DRAWING CS- air cooled with soundproofing casing
{1 Dimensions specially
for CS 120:
o
N
| /  >
NY N. ~
a — 1
sano aces ra _/
Control panel
ook cc
<j — о
o J
Y Control
Cooling cabinet Cooling
air outlet air inlet
«— Q «т
o о
J L
63Ya
70
Air discharge diameter 2 NPTM
dia.
Openings for
electrical connection
BS/CS 3 - 09.82
12. TRANSPORTATION INSTRUCTIONS
Mode! Weight
BS 44 approx. 1520 Ibs.
BS 50 approx. 1850 lbs.
BS 60 approx. 1940 lbs.
CS 75 approx. 2490 Ibs.
CS 90 approx. 2600 lbs.
CS 120 approx. 2930 Ibs.
Dimensions in inches
Ne
A ;—_—] e ;_—
— mm
EE
Ea]
|
PP =]
ет
Figure 31
——
1
min.40
Figure 30
KAESER
COMPRESSORS
— Eye bolt for BS: M 20
/ Eye bolt for CS: M 24
do
Figure 32
lift truck
26
BS/CS 3-09.84
LRT El TE Ma dad
PRESSORS
13. Conversion instructions for Screw Compressors Model BS/CS
from soundproofed to super soundproofed design
Demount the steel plate with filter Screw the quick-changeable frame
frame at the right end off the steel plate
Screw the quick-changeabie frame Fasten the screws in the threads of
on silencing box the supporting frame (at both ends
of the unit)
Screw the extra plate (delivered with
the other parts) on frame and now
fasten the two boxes on both ends
of the unit with hexagon nuts
27
BS 50
BS 60
— PARTS MANUAL
- RECOMMENDED
SPARE PARTS LIST
A 20
B 20
C 20
D 20
SECTION 1
AA
SECTION 2
@. SECTION3
Lo
ed
“rat
-
=
INDEX
Page No.
Introduction 3
Foreword
Description
To order parts
Recommended spare parts
Caution
Parts list 4-15
Recommended spare parts 16 - 19
re
a
SECTION 1 .- INTRODUCTION
1. FOREWORD .
This manual is provided for the operator's use and reference when ordering parts.
An illustrated parts breakdown is included for parts identification. All compressor
parts meet the manufacturer's highest quality standards used in the manufacture
of the original equipment,
2. DESCRIPTICN
The parts breakdown lists cvery part, assembly and sub-assembly of the compressor
unit. Each part is identified with a number. The location of and relationship between o
parts: are clearly illustrated. Questions pertaining to the number, description and
quantities needed for each assembly are dealt with in the following pages.
3. TO ORDER PARTS
Wnen ordering parts, furnish the following information tc prevent any error:
- Model designation and serial number of the unit as shown on compressor
nameplate. -
- Reference number, part number, description and quantity required as listed.
4. RECOMMENDED SPARE PARTS LIST
A recommended spare parts list is provided at the end of this manual. The list
indicates the description, part number, the quantity used in the compressor, and |
minimum quantities which shouid be carried to ensure maximum protection of o
the compressor. The recommended spare parts inventory to be kept on hand varies
according to the lccation of the nearest distributor, and is broken down as follows:
A. Local distributor
B. Nearby distributor
C. Remote distributor.
5. CAUTION
NEVER use parts other than the ones approved by the manufacturer and listed in
this parts manual. The use of parts not approved by the manufacturer may result
in hazardous conditions, over which the manufacturer has no control, bodily injury,
and damage to the compressor unit. Such action would invalidate the manufacturer's?
warranty of the compressor unit.
SECTION 2 PARTS
Title
Frame, Casing
Ж Driving system
Oil tubes, Vent lines
LIST
Control tubes, Compressed air tubes
Vent valve
Inlet valve
Check valve
Minimum pressure check valve
Combination valve
Page
No.
6,7
"12
14
Frame, Casing = BS 50, BS 60 type
— 5
—
3
Ë
7.
?
Ref. |Qty {Part № Description Ref. |Qiy [Part No Description
1 } 4,9370.0! Frame
1) 2 i 7.2305.n Controller : 3] 4 6.0653.0 ISpring wosher
27 2 | 7.2306.0 | Controller , 32 2 6.0560,0 |Toothed lock washer
3 tH 1.4.9257 Casing complete with Ja 33 ? &.0581.0 |Нех. по! М 5
ad | 6.1932.0 | Quick-change frame ; 34 2 6.0682.0 |Hex. nut M 6 |
a] 1 | 4.7019.1 | Casing 35 | 4 |6.0684.0 [Hex. nt M8 O
5 1 4.8324 ,0 | Casing 1
e 6 } 4,8325.0 Casing
ad 7 1 4.7071.1 | Door
8 | 4.7072.1 | Door
pa 9 1 4.8323,0 | Door
- 10 i 4.7070.1 | Cover sheet | 1) Compressor Unit BS 50
11 1 4.8305.0 | Cover plate 2 Compressor Unit 85 60
12 1 4.7349,0 | Fitter mat 4 }
13 1 4,7347.0 | Filter mat |
14 1 6.1938,0 | Filter mat
15 1 4.7318.0 | Covering groting
16 1 4.7346,0 | Covering groting
17 4 6,1347.0 | Anti-vibration pads dia .35/8x 3578"
18 2 5.1331.0 | Gas spring
19 | 5.1398.0 | Gasket profile 185“
20 1 5.1403,0 | Froth rubber band 13*
21 4 5.1330,0 | Split pin .
22 1 6.2M4,01 Stud M10 x 35 ,
23 | 49 6.0716.0 | Philips head screw M 5 x 10
24 2 6.0701 ,0 | Philips head screw M5 x 15
25 3 6.0786 ‚0 | Sheet metal screw 35x95
26 4 6.0726.0 | Hex. hd, screw M 39 « 20
27 4 6.72203.0 | Hex, hd. screw M 16 x 20
28 2 6.0622,0 | Washer
29 12 6.0623.0 | Washer
JO 4 6.0827.0 | Washer
ERE
à
Driving system | BS 50, BS 60 type
4-6)
O |
Ref. |Qty |Part No Description Ref. [Qty Part No | Description
| 1 1,3851 .3 Screw compresso. Sigma 2 21 I 4,7207 .i Intermediate ring
1-3) 2} 1 7.0940.0 | Motor 3-phase 30 kW, 230/660 V 22) | 4,7225.0 | Intermediate ring
4-6) ?| | 7.0941.0 | Motor 3-phase 37 kW, 230/460 V 231 1 4.8321.0 | Distance washer
1-3) 3} 1 4,7283.1 | Motor pulley dia, 12 19/32" 24) 9 6,0725.0 | Hex. hd. screw MB x 15
al 1 4,7284,1 Motor pulley dia. 12 19/32” 25| | 6,0730,0 Hex, hd, screw MB x 40
41 1 4.9876.0 | Compressor pulley dia.8 3/16° . 26| 2 &.0763.0 | Hex. hd, screw M 10 x 30
2) 41 1 L.98770 | Compressor pulley dia.9 39/64‘ 27| 1 6,0772.0 | Hex. hd. screw M 10 x 55
3} 41 1 4.9878.0 | Compressor pulley dial] 17/64" 281 | 6,0798.0 | Hex. hd. screw M JO x 70
4) 4 1 £.9879.0 | Compressor pulley diab 11/16" 279| 2 6.2215.0 {| Hex. hd. screw M12 x 25
5) 41 | 4.3880.0 | Compressor pulley dia7 43/64" 1-3) 301 4 6.0799.0 Hex. hd, screw ВМ 12 x 75
6) 41 1 L.3881.0 | Compressor pulley dia.8 13/16" 4-6) 30j 4 6.0819.0 Hex, hd. screw М 16 х 60
1) 5] 6.1434 0 | Set of v-belts ‚ MN] 4 6.2210,0 | Hex. hd, screw M 14 x 40
2) 51 | £.2933.0 | Set of v-belts Je) 4 6.2200,0 Hex. hd. screw M 14 x 60
3) 51 1 6.2542.0 | Set of v-belts 33| 5 6.0813.0 | Hex. hd. screw M 16 x 40
4) 5) 1 6.2532.0 Set of v-belts 1-3} 34 } 6,0795,0 Hex, hd, screw M 20 x 100
5) 5| 1 76.1434.0 | Set of v-belts 1-6) 341 | 6.0777.0 | Hex. hd. screw M 20 x 65
5) 51 1 6.2533.0 | Set of v-belts 351 3 6.0617,0 | Split pin
61 1 5.0684.0 [ Fon wheel 36 | 10 6.0623.0 | Wosher
71 1 5.1074.3 | Cooler 37] 2 6,0811,0 | Washer
8] 1 4,8328.0 | Fan cose 38} 2 6.0624.0 | Washer
Gi 1 Sk 1426.73] Cover plate 1-3 371 4 6.0625.0 | Washer
lof 1 4,8377 1 Swing frame -6) 371 4 6.0627.0 | Weasher
iy 1 4.7564,1 | Balonce adjustment = 40| 4 6.0633,0 | Washer *
12) 1 4,8326.0 | Whip -6) 40 | 4 6.2376.0 | Wa:her
131 1 14.7572.1 | Shoft 41 2 6.0533.0 | Washer
141 1 4,8322.0 | Pivol beoring 421 8 6.0426.0 | Washer
15] 4 6.1329.0 | Base of the machine _ 43] 8 6,0527 .0 { Washer
1-3 16] 4 4,7593.0 | Steel plate 441 2 6.0629.0 | Washer
17] 2 4.7428,0 | Hinge 45110 6.0653.0 | Spring washer
te) | 4,7588.1 | Centering disk 46 | 2 6,0654.0 | Spring washer
19| | 4,7592.0 | Disk -2) 47 | 4 6.0635.0 | Spring wosher
20 | 5.0428.0 Disk -6) 47 4 6.0457 .0 Spring washor
Driving system
3
42
L-
. Y
48
a es
£3 -r
“=
+
Ref. {Qty [Fart No Description -
48] 4 6.0656,0 | Spring washer
49] À 6.0657.0 | Spring wosher
0 2 6.0584,0 | Hex. nut MB
— St 4 6,0685.0 Hex. nut M 10
1-3) 52 4 6.0686.0 | Hex. nut M12
4-6) 521 4 6.0688,0 | Hex, nut M16
54 8 $.0687.0 | Hex. nut M14
54] 4 6.0688.0 | Hex. nut M16
55! 2 6.0593.0 } Hex. nut M 20
1) Compressor Unit BS 50; 110 psig
2) Compressor Unit 85 50; 145 psig
3) Compressor Unit BS 50; 190 psig
4) Compressor Unit BS 60; 110 psig
5) Compressor Unit BS 60; 145 psig
6) Compressor Unit BS &0; 190 psig
BS 50, BS 60 type
Oil tubes , Vent lines
BS 50, BS 60 type
TR
FALL
1
Moo
„от 3 ha
7” so" 1 a
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Ds Di "e E y
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Ref. |Qty {Port No Description Ref. | Qty [Part No Description
1 | à |4.8870.1 | Combination valve | 31 | 2 |5.0567.1 | Gosket for inlet valve
2 1 16.1981.0 | Filter cortridge 32 1 16.1524.0 | Gasket R 1/2"
3 1 17,1366.0 | Oil stop volve R 3/4" 33 | 4 |6.2411.0 | Cylinder screw with inside hex.
4 1 4.7387 1 Inlet valve D M6 x 100
5 ! 4,7345.0 | Vent valve R 1/2" 34 4 |6.2342.0 | Stud M 10x 65
O 6 1 6.1917.0 | Air filter complete 35 2 6.0631.0 | Washer
67 ] 6.1976.0 | Filter cartridge 34 2 6.0684.0 | Hex. nur MB
г —6 | 1. (6,1920.0 | Support for air filter 37 | 4 |6.0685.0 | Hex. nut M10
о 7 1 14.7324.2 | Flonge й 38 | 1 |6.1527.0 | Gasket R34"
8 1 7.0294.0 Vacuum switch (-B 1/16 wg)
“ 9 Ï 7.0298.0 Protecting cap
10 1 В.0259.0 Bal! cock R 1/2"
1 1 4.1850.0 | Copper tube
12 1 4,8307 .0 Tube
13 | 8.0864.0 | Hose line R 1/2"x19 11/16 |
14 ) 8.1139 0 | Hose line R 3/4"x28 47/64
15 ] Hose line R 1/8”! 49/64 “
ló ] 7.1078.0 | Hose R3x25 25/64 “
7 2 ?.0059.0 Hose clip
18 | 6.1949 .0 Silencer
19 | 6.1113.0 | Angle R 3/4"
20 1 |6.4062.0 | Elbow R 1/2"
21 2 15.0784.0 | Double nipple R 1/2" .
22 ] 5.0785.0 | Double nipple R 3/4"
23 1 6.1030, 1 Fitting R 1/2"
24 l 6.1033.0 | Fitting R 3/4"
25  5.0725.0 {| Reducing socket R 3/4" x R 1/2"
26 1 6.0274 .0 Pipe fitting R 3/4"
27 1 le.0251.0 | Angle fitring R 1/8"
29 ) 6.0257.0 Angle fitting R 3/4"
27 2 5.1423,0 | O - ring dia. 3/4x1/8"
30 ! 5 .0532.0 Rubber sleeve ,
EEE»
Tala.
Control tubes,
Compressed air tubes
1
2)
3)
1)
3)
2)
3)
1.
Ref
ra o AA
= = канон
de 63 ко ==
0 Co 9 CO 5! Os Ln
BS 50, BS 60 type:
Qty Part No Description
1 13,5056.4 | Tonk 13gal. /203psig
1 4.7238.1 Сомег
1 6.1960.0 Oil séporator cartridge
] 4,7342.0 | Minimum pressure check valve R11/2'
1 4.7393.1 | Check valve complete
1 7.0217.0 | Difference pressure switch
1 7.1369.0 | Solenoid valve
} 7.0220.0 | Pressure switch 116 psig
1 7.0221.0-} Pressure switch 232 psig
1 7.0221.0 | Pressure switch 232 psig
1 7.0219.0 | Pressure switch
1 8.0018.0 | Pressure gauge 0-360/220 psig
1 8.0137.0 | Pressure gauge О - 145/110 psig
1 8.0135.0 | Pressure gouge 0 = 232/145 psig
1 8.0138.0 | Pressure gauge 0 - 232/190 psig
| 8.0332.0 | Safety volve R 3/4", 130 psig
1 8.0334.0 | Safety valve R 3/4", 175 psig
1 8.0336.0 Safety valve R 1/2", 210 psig’
1 8,0177.0 Distance thermometer
2 7.0784.0 | Hour meter
1 7.0449.0 Malfunction relay
] 7.1083,0 | Luminous bulton green
| 7.1084.0 | Luminous button red
1 8,0259,0 Ball cock R 1/2"
| [8.0381.0 | Diet trop R 1/4"
2 6.0105.0 | Oil sight gless R 3/4"
1 6.0501.0 { Locking screw R3/8°
1 9.0817.0 } Hosa coupling R 1/4"
1 9.0814,0 | Hose coupling R 3/9"
1 6.0519.0 | Locking screw R 1 1/4"
1 4.7454.0 | Instrument pone!
3)
. [ay
Part No
Description
2 4.8435.0 | Steel piote
3 5.1125.0 | Tension clomp complete
3 5.1371,0 | Gosket ring
3 5,1122,0 | Support for gasket ring
3 4.8268.0 | Sleeve
1 4,8307.1 | Air tube o
1 4,8308,0 | Air tube
 4.8317,0 | Suction tube
1 4.8257.0 | Copper tube R 1/8"
1 4.8330,0 | Cepper tube R 1/8"
1 4.8329,0 | Copper tube R 1/8"
| 4.8332.0 | Copper tube R 1/8"
] Control tubeR 1/4"x13"
1 Control tubeR 1/4"x16 59/64"
1 Control tubeR 1/4"x17 23/32°
1 Control tubeR 1/4"x51 11/64" _
1 8.1130.0 | Hose line R 1/4"x27 9/16”
| 8.0581.0 | Hose line R 1/2"x 59%
1 16.1098.0 | Angle RI 1/2"
1 5.0929.0 i Protection sleeve R 3/8"
| 5.0780.0 Double nipple R 1/4"
i 5.0795.0 | Double nipple R 1/4" x M12 x 1,5
2 5.0820.0 | Reducing socket R 1/4" x R 1/8%
 5.0846.0 | Reducing socket R 1/2" x R 1/8"
1 5.0963.0 | Reducing socket R 1/2" x R 1/4"
] 5.0925.0 | Reducing socket R 3/4" x R 1/2"
} 6.0390.0 | Pipe fitting R 1/4"
] 4.0231.0 | Pipe fitting R 1/8"
5 6.0246.0 | Pipe fitting R 1/8"
! 4,8199.0 | Pipe fitting R 1/4"
| 4.8335.0 | Pipe fitting R 1/4"
1 16.0229.0 | Pipe Fitting R 1/4"
Control tubes,
Compressed air tubes
- BS 50, BS 60 type
Ref. {Gty Part No Description
58 3 6.0266.0 | Angle fitting R 1/8"
59 ] 5.0254.0 | Angle fitting R 1/4"
60 2 6.0344.0 | T pipe fitting R 1/8"
61 2 17.0673.0 | Plug PG 16
62 1 5,1443.0 | O-ring dia. 25/32¢x3/32"
63 1 5 1455.0 | O-ring dic, V 27/32x5/64"
. 6A 1 5.1422.0 | O-ring dia. 2 13/64x1/8"
La 65 | 1 15.1462.0 | O-ring dic. 3 5/32x5/64"
a 66 2 6.0470.0 | Gasket for pressure gauge R 1/4"
pes 67 2 6.0432.0 Gasket R 1/4"
68 | 3 |6.1521.0 | Gasket R 3/8"
69 2 |6.0438.0 ¡ Gosker R 1/2"
3) 70  6.1524.0 | Gasket R1/2"
71 ] 6.1527.0 | Gosket R 3/4"
72 2 5.0556.0 | Gasket for tonk
73 6 6.0914.0 | Philips head szrew M4 x 10
74 2 6.0960,0 | Fillister heod screw M 4 x 8
75 2 6.0746.0 Hex. hd. screw M6 x 10
76 2 6,72214,0 Hex. hd, screw MB x 30
77 4 6.0733.0 | Hex. hd. screw M 8 x 60
78 4 6.0780.0 | Hex. hd, screw M10 x 110
79 2 6.0821.0 | Hex. hd. screw M 10 x 40
80 8 6.0759.0 | Hex. hd, screw M16 x 45
Bi 6 6.2374.0 | Washer
82 2 6,2373,0 | Wosher
83 6 16.2421.0 | Hex. nut M8
1) Compressor Unit 130 psig
2) Compressor Unit 145 psig
3) Compressor Unit 190 psig
020)
/
Mer Fea
„ FA
E
Vent valve
4.7345.0
BS 50, BS 60 type
£
Ret. | Qty {Part No Discription
1 1 5,0787.0 | Crankcase
2 1 5,0797.0 | Cover
3 1 A.9026.0 4 Piston complete
Jo 1 5.0978,0 | Piston +
+ 3b 1 5.1473.0 | O-ring dia. 5/8x3/32" |
4 1 5.0797.0 | Diophrogm ©
5 4 6.2408.0 | Cylinder screw with inside hex.
M5x12
6 6,2482,0 | Stud bolt M5 x B
Я чат пня Ме my A rt отн =
BS 50, BS 60 type
Inlet valve
4.7387 .1
Ref. | Qty | Part No Discription
1 1 4,8930, 2 | Valve body
2 1 à .8963,0 | Shoft
3 1 4,8732.0 | Disk
4 1 4,8964.0 | Lever
O > 1 4.89461,1 1 Support
6 1 4.8965,0 | Hex, nut .
= - 7 1 7.0486.0 {Working cylinder
i 8 I 7.0489.0 | Angle joint
9 2 6.0033.0 | Boll bearing
у 10 2 .| 6.0541.0 | Guard ring
11 1 4.7564,0 |Rivet with button head
12 1 6.0¢09.0 | Clomping slceve
13 2 6.0720.0 |Hex. hd. screw M 6 x 15
14 1 6.0723.0 Hex. hd. screw M6 x 45
15  6.0701.0 [Cap nut M 6
3 6,0622.0 {Washer
i
"
KARL
ww
4.7393.1
Check valve
BS 50, BS 60 type
Ref. | Qty [Part No. Discription.
1 1 4.8910,2 [Valve body
2 | 5.0617 ,1 [Compression spring
3 1 4,9011.0 | Valve disk complete
Ja | 4, 8916,0 {Guide bolt
3b 1 4.6915.2 [Disk
Зе | 4.8914.) [Disk
3d | 1 5.0565,1 |Gosket
3e 1 6.0700,0 | Crown nut MIO
3f | | 6.0649.0 {Split pin dio. 2 x 20
Minimum pressure 2. -— BS 50,B560 type
check valve : |
4.7342.0
ren
LI
byt
E
Ref. | Qty | Part No. Discription
i 1 4.8575,0 | Valve body R 1 1/2"
2 1 4.857 6,0 | Cylinder
3 1 (4.9021.9 Piston complete
3a 1 4.8578.0 {| Piston ,
3b 1 5.1434.0 | O - ring 1 7/64x1/8
Зе 1 5.1411,0 | O- ring 1 1/32x5/37"
4 ] 4,9015.0 | Valve disk complete *
de 1 4.5568.0 | Bolt
4b 1 4.8577 .0 | Disk
de 1 3.1434.0 | O-ring V-27/64%1/8"
‚5 1 6.2371.0 | Disk
6 1 5.1470.0 | O- ring 1 49/64x1/8"
7 1 5.0543.0 | Compression spring
8 | 3.0645.0 | Compression spring
9 1 6.0586.0 | Hex, nut M12
10 1 6.0745.0 | Sauare-haod bolt M 12 x 40
Combination
4.8870.1
valve
- BS 50, BS 60 type
Ref. | Qty [Part No Discription
] Ï 4.88/2,1 | Valve body
2 1 4,8875.0 | Cover
3 1 4,8873,0 | Соуег
4 1 7.0379,0 |Actuoting piston with working element
3 1 4,8874.1 | Thread nipple
6 | 5.0636,0 | Compression spring
7 2 5.14450 | O-ring dia. 1 3/8x5/64"
8 1 7,1407,0 | Difference pressure switch
9 3 6.2406.0 | Cylinder screw with inside hex,
М 5х 16
10 3 6.2400.0 {Cylinder screw with inside hex,
М 5х 20
1 ] 6.1534,0 |Gosket dia, 25/32" dia. 15/16x1/16
SECTION 3 RECOMMENDED SPARE PARTS LIST
“Model BS 50 / 60
DESCRIPTION part | QY- LOCATION / USE Recommended
No per Quantities
” unit A|B|C
Lubricating oil filter element 6.1981.0 1 at valve combination 1 | 2 3
Oil separating cartridge 6.2012.0 1 in oil separator 1 1 2
complete set :
Intake air filter cartridge 6.1996.0 1 at air intet port 2 | 3 4
Filter mat 6.1938.0 1 at cooling air inlet port 2 3 4
V-belt set for BS 50/110 psig | 6.1434.0 1 [at motor/compressor pulley 1 | 1 2
@ 625336145 psig 85| 1. " т |1 | 2
xi 190 psig | 6.2542.0 1 " 1 1 2
[email protected] V-belt set for BS 60/110 psig | 6.2532.0 1 at motor/compressor pulley 1 1 2
| 145 psig | 6.14340. 1 и 1 11 2
190 psig | 6.2533.0 1 " 1 1 2
Valve plate complete 4.9011.0 1 in check valve 1 1 2
Valve plate complete 4.90150 1 in minimum pressure check valvel 1 1 2
Inlet valve complete 4,7387.1 1 suction side of airend 0 1 1
Compression spring 5.0617.1 1 in check valve 0 | 1 1
Compression spring
1/64" x 5/16" x 1 13/32" 5.0643.0 1 in minimum pressure check valve] 0 | 1 1
Compression spring |
5/32" x 63/64" x 7 9/32" 5.0645.0 1 {in minimum pressure check valve 0 | 1 1
O-ring inside dia. 3/4"x1/8" 5.1423.0 2 | at valve combination 1 1 2
O-ring ins.dia. 1 27/32"x5/64" | 5.1455.0 1 at oil filler neck 1 1 2
Flat gasket 5.0567 .1 2- | at inlet valve i 1 2
O --ring ins.dia. 25/32"x3/32" 5.14430 1 in dirt trap 1 td 2
13 O-ring ins.dia. 3 5/32"x5/64" 5.1462.0 1 ¡between airend and check valve | 1 | 1 2
_ O-ring ins.dia. 2 13/64"x1/8" 5.1422.0 1 between check valve and fitting { 1 1 2
- Gasket ring ins.dia. 1 57/64" 5.1391.0 3 pipe gasket: 2 separator/cooler 1 1 2
` | 1 airend/separator .
O-ring ins.dia. 1 3/8"x5/64" 5.14450 2 in valve combination 1 1 2
O-ring ins.dia. 1 1/32"x5/32" | 5.1411.0 1 fin minimum pressure check valve) 1 | 1 | 2
O-ring ins.dia. 1 49/64"x1/8" 5.1470.0 1 In minimum pressure check valve] 1 1 | 2
Diaphragm 5.0999.0 -| 1 in vent valve i 1 2
Diaphragm 7,0347.0 | 1 in oilstop valve 1 |1 2
Mains pressure switch for :
110 psig units 7.0220.0 i control line from air cooler O | 1 1
Mains pressure switch for
145/190 psig units 7.0221.0 1 control line from air cooler 0 | 1 1
Safety pressure switch 7.0219.0 1 control line from airend outlet O +1 1
Valve combination : 4.8870.0 1 at oil cooler. 0 | 1 2
ha
24
Si
| Но.
RECOMMENDED SPARE PARTS LIST
A
Model BS 50 / 60
DESCRIPTION Part |Qt.- LOCATION / USE Recommended
No per Quantities
” unit A | BIC
Oil stop valve R 3/4 SK2881.73| 1 at valve combination 0 | 1 2
compl. pasted
Discharge valve R 1/2 sK2602.731 1 at pipe oil separator / o | 1 +
compl. pasted minimum pressure check valve |
Silencer 6.1969.0 1 in 80° elbow before inlet valve 010 1
Dirt trap R 1/4" 8.0381.0 1 in oil return line from oil ol:
: separator to airend
Hose line R1/4'"x27 9/16" 8.1130.0 1 | control line to safety pressure |'9 | 4 | 0
switch e
Hose line R1/2"x19 11/16" 8.0864.0 1 discharge valve to silencer 1
Hose line R3/4"x28 47/64" 8.1139.0 1 oilstop valve to airend 1 1
ri " : |
Control válve R 1/8 sK?2866.73| 1 at pipe oil separator / ola 4
compl. pasted minimum pressure check valve :
Piston compl. with O-rings 4.9021.0 1 in minimum pressure check valve 1 1 2
RECOMMENDED SPARE PARTS LIST
FOR ELECTRICAL EQUIPMENT
Model BS 0
WYE-Delta-start
-
2 OL CR1 jCR2CR3 TRITR
- 112
WRE DUCT
T
1M 2M ЗМ
101.
| [emos TA
1 1
Qty. Input voltage Recommended
DESCRIPTION per | Part No. LOCATION/USE | Quantities
unit 208 vI230 Vi4560 V a B C
LM vot tart (Mai tact 1 7.2063.0 X X
Motor starter i a с
n contactor) 7 2067.0 x Control box 0 1 1
7.2063.0 X X ;
2 M Motor starter (Delta contactor) 1 7.2067.0 x Control box Го 1 1
7,2062.0 X X’
VW „а
3 M Motor starter (WYE contactor) 1 7 2060.0 x Control box | Q 1 1
2 OL Overload relay for transformer 1 7.2201.0 | x X X Control box | 0 |'1 | 1
7.2224.0 X
Transformer 1 Control box | 9 1
T 7.2221.0 x | x 1
CR 1,2,3 | Control relay 3 17.2066.0| x | x | x | control box [0 | 1 1 1
TR 1 Time delay relay (delay off) 1 7.0467.0 X X X Control box | Q l 1
TR 2 Time delay relay (WYE time) 1 7.0466.,0 X X X Control box | l 1 2
1 OL Overload relay for motor 1 7.2252.0 ^ . Control box 10 1:1 1
, 7.2250.0 x
1
a
a
pl.
,
5
BRAT
RECOMMENDED SPARE PARTS LIST
FOR ELECTRICAL EQUIPMENT
Model BS 60
WYE-Delta-start
, 2 OL CR1 [CRZFER3 TRITR
112
WRE DUCT
T
1M 2H 3M
"10L
| vermioaks Had
Qty. Input voltage ‚ | Recommended
DESCRIPTION per | Part No. LOCATION/USE | Quantities
unit 208 V1230 V [460 Vv A n С
. i 7.2063.0 x x
1 M Motor starter (Main contactor) 1 ;
7.2062. 0 x Control box 0 1 1
>. м a 7.2063.0 | x X -
otor starter (Delta contactor) 1 7.2063. 0 x Control box О 1 1
su wor , 7.2062.0 | X X’ - a
Or starte WY E E t
E contactor) 1 7.2067.0 x Control box 0 1 1
2 OL Overload relay for transformer 1 7.2201.0| x X X Control box { 0 1 1
T.2224.0 X *
T Transformer 1
7-2221.0 x x Control box 0 1 1
CR 1,2,3 | Control relay 3 7.2066.0 X X X Control box | O 1 1
TR 1 Time delay relay (delay ofE) 1 7.0467.0 X X X Control box 0 1 1
TR 2 Time delay relay (WYE time) 1. |7.0466.0 X X X Control box | 1 l 2
1 OL Overload relay for motor 1 7.2253.0 X X
7.2251 0 х Control box 0 1 1

Manual Kaeser Csdx t

Short Description

Instruction manual for Kaeser CSDX T screw compressor.

Description

Инструкция по эксплуатации Винтовой компрессор CSDX T

KAESER KOMPRESSOREN 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com

Оригинал инструкции /KKW/SCSDX 2.02 ru SBA-SCHRAUBEN-T-SC /KKW/SSC 2.02 20120417 134352

К этому документу 1.1 Порядок обращения с документом . 1.2 Дополнительные документы . 1.3 Авторское право . 1.4 Символы и условные обозначения . 1.4.1 Указания по предупреждению . 1.4.2 Предупреждения нанесения материального ущерба . 1.4.3 Дополнительные указания и символы .

Технические характеристики 2.1 Фирменная табличка . 2.2 Опции . 2.3 Вес . 2.4 Температура . 2.5 Окружающие условия . 2.6 Вентиляция . 2.7 Давление . 2.8 Производительность . 2.9 Рекомендуемые охлаждающие масла . 2.10 Количество заливаемого охлаждающего масла . 2.11 Двигатели и мощность . 2.11.1 Двигатель компрессора . 2.11.2 Двигатель вентилятора . 2.11.3 Двигатель вентилятора . 2.12 Звуковое излучение [дБ(А)] . 2.13 Электрическое питание . 2.14 Характеристики электрического подключения . 2.14.1 Частота сети: 50 Гц . 2.14.2 Частота сети: 1000 м . 2.15 Водяное охлаждение . 2.15.1 Водяное охлаждение (пластинчатый теплообменник) . 2.15.2 Водяное охлаждение (трубчатый теплообменник) . 2.16 Система рекуперации тепла . 2.16.1 Подготовка для внешней системы рекуперации тепла . 2.16.2 Внутренняя система рекуперации тепла . 2.17 Холодоосушитель .

4 4 5 5 5 6 6 7 7 10 11 11 12 12 13 13 14 14 15 16 17 19 20 20 21 22

Техника безопасности и ответственность 3.1 Основополагающие сведения . 3.2 Применение по назначению . 3.3 Применение не по назначению . 3.4 Ответственность пользователя . 3.4.1 Cоблюдение законодательных предписаний и общепризнанных правил . 3.4.2 Определение персонала . 3.4.3 Соблюдение сроков технического освидетельствования и правил по профилактике несчастных случаев . 3.5 Источники опасности . 3.5.1 Безопасное обращение с источниками опасности . 3.5.2 Безопасное применение машины . 3.5.3 Организационные мероприятия . 3.5.4 Опасные зоны . 3.6 Предохранительные устройства . 3.7 Знаки безопасности . 3.8 В аварийной ситуации . 3.8.1 Правильные действия в случае возникновения пожара .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

24 24 24 25 25 25 26 26 26 29 31 31 32 32 34 34

3.8.2 Оказание помощи при травмировании охлаждающим маслом . 3.8.3 Оказание помощи при поражении или отравлении хладагентом . 3.9 Гарантия . 3.10 Охрана окружающей среды .

Устройство и принцип действия 4.1 Корпус . 4.2 Принцип действия машины . 4.2.1 Холодоосушитель . 4.2.2 Беспотенциальные контакты . 4.3 Параметры . 4.3.1 Прикручивающиеся опоры машины . 4.3.2 Водяное охлаждение . 4.3.3 Фильтровальный мат для охлаждающего воздуха . 4.3.4 Система рекуперации тепла . 4.4 Рабочие режимы и виды регулирования . 4.4.1 Рабочие режимы машины . 4.4.2 Виды регулирования . 4.5 Виды регулирования холодоосушителя . 4.6 Предохранительные устройства . 4.7 Панель управления SIGMA CONTROL 2 .

37 37 39 39 39 39 40 40 41 42 42 43 44 45 46

Условия установки и эксплуатации 5.1 Обеспечение техники безопасности . 5.2 Условия в месте установки . 5.2.1 Определение места для установки и расстояний . 5.2.2 Обеспечение вентиляции машинного помещения . 5.2.3 Проектирование канала отточной вентиляции . 5.3 Эксплуатация машины подключенной к пневмосети .

Монтаж 6.1 Обеспечение техники безопасности . 6.2 Информирование о повреждениях при транспортировке . 6.3 Подключение машины к сети сжатого воздуха . 6.4 Электрическое подключение . 6.4.1 Холодоосушитель: согласование с напряжением сети . 6.5 Подсоединение системы отвода конденсата . 6.6 Опции . 6.6.1 Крепление машины . 6.6.2 Подсоединение системы водяного охлаждения . 6.6.3 Подсоединение системы рекуперации тепла .

53 54 54 55 55 56 57 57 57 58

Ввод в эксплуатацию 7.1 Обеспечение техники безопасности . 7.2 Перед вводом в эксплуатацию . 7.3 Контроль выполнения требований монтажа и эксплуатации . 7.4 Установка магнитного пускателя . 7.5 Регулировка защитного автомата двигателя . 7.6 Заливка охлаждающего масла в компрессорный блок . 7.7 Включение и выключение регулирования ЧАСТИЧНОЙ НАГРУЗКИ . 7.8 Первое включение машины . 7.9 Установка заданного давления сети . 7.10 Изменение языка индикации .

60 61 61 62 62 63 64 65 66 66

Эксплуатация 8.1 Включение и выключение . 8.1.1 Включение .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

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8.1.2 Выключение . Включение и выключение в аварийной ситуации . Включение и выключение с дистанционного пульта . Включение и выключение при помощи таймера . Эксплуатационные сообщения . Квитирование сообщений о неисправностях и предупреждениях .

Распознавание ошибок и их устранение 9.1 Основополагающие сведения . 9.2 Прочие неисправности .

Техническое обслуживание 10.1 Обеспечение техники безопасности . 10.2 Соблюдение сроков техобслуживания . 10.2.1 Документирование работ по техобслуживанию . 10.2.2 Возврат счетчика часов технического обслуживания в исходное положение . 10.2.3 Регулярные работы по техобслуживанию . 10.2.4 Интервалы замены охлаждающего масла . 10.2.5 Регулярные профилактические работы . 10.3 Очистка или замена фильтровального мата распределительного шкафа . 10.4 Техобслуживание радиатора . 10.5 Техобслуживание системы водяного охлаждения . 10.6 Очистка или замена фильтровального мата охлаждающего воздуха . 10.7 Техобслуживание системы рекуперации тепла . 10.7.1 Внешняя система рекуперации тепла . 10.7.2 Внутренняя система рекуперации тепла . 10.8 Замена воздушного фильтра . 10.9 Техобслуживание двигателей . 10.10 Проверка муфты сцепления . 10.11 Проверка предохранительного клапана . 10.12 Проверка предохранительного отключения при повышенной температуре . 10.13 Проверка уровня охлаждающего масла . 10.14 Сброс давления из машины . 10.15 Доливка охлаждающего масла . 10.15.1 Сброс давления из машины . 10.15.2 Доливка охлаждающего масла и проведение пробного запуска . 10.16 Замена охлаждающего масла . 10.17 Замена сменного элемента масляного фильтра . 10.18 Заменить сменный элемент маслоотделителя . 10.19 Техобслуживание холодоосушителя . 10.19.1 Очистка конденсатора . 10.19.2 Техобслуживание системы отвода конденсата . 10.20 Документирование работ по профилактике и техобслуживанию .

76 78 79 79 80 81 82 83 83 83 83 84 85 86 87 88 88 90 91 92 93 98 99 101 102 102 104

Запасные части, эксплуатационные вещества, техническое обслуживание 11.1 Обратите внимание на фирменную табличку . 11.2 Заказ запасных частей и эксплуатационных материалов . 11.3 KAESER AIR SERVICE . 11.4 Координаты сервисных центров . 11.5 Запасные части для профилактики и ремонта .

Снятие с эксплуатации, складирование и транспортировка 12.1 Снятие с эксплуатации . 115 12.2 Упаковка . 115 12.3 Хранение . 116

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

12.4 Транспортировка . 12.4.1 Безопасность . 12.4.2 Транспортировка машины с помощью вилочного погрузчика . 12.4.3 Транспортировка машины с помощью крана . 12.5 Утилизация . 13

Приложение 13.1 Технологическая схема трубопроводов и инструментов (R+I — схема) . 13.2 Технологическая схема трубопроводов и инструментов (R+I-схема) Регулирование ЧАСТИЧНОЙ НАГРУЗКИ . 13.3 Габаритный чертеж . 13.4 Электрическая схема .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

116 116 116 117 117 119 125 131 135

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Рис. 1 Рис. 2 Рис. 3 Рис. 4 Рис. 5 Рис. 6 Рис. 7 Рис. 8 Рис. 9 Рис. 10 Рис. 11 Рис. 12 Рис. 13 Рис. 14 Рис. 15 Рис. 16 Рис. 17 Рис. 18 Рис. 19 Рис. 20 Рис. 21 Рис. 22 Рис. 23 Рис. 24 Рис. 25 Рис. 26 Рис. 27 Рис. 28 Рис. 29 Рис. 30 Рис. 31 Рис. 32 Рис. 33 Рис. 34 Рис. 35 Рис. 36 Рис. 37 Рис. 38 Рис. 39 Рис. 40 Рис. 41 Рис. 42 Рис. 43 Рис. 44 Рис. 45 Рис. 46

Максимальная относительная влажность всасываемого воздуха . Расположение знаков безопасности . Изображение корпуса . Изображение машины . Холодоосушитель . Прикручивающаяся опора машины . Водяное охлаждение (опция K2) . Водяное охлаждение (опция K9) . Фильтровальный мат для охлаждающего воздуха (опция K3) . Внутренняя система рекуперации тепла (опция W2/W3) . Изображение кнопок . Обзор индикаторов . RFID-считывающее устройство . Рекомендации по установке, размеры [мм] . Воздухопровод . Система отвода конденсата, размеры [мм] . Подсоединение системы водяного охлаждения . Подсоединение системы рекуперации тепла . Заливное отверстие на впускном клапане . Муфта сцепления . Регулирование ЧАСТИЧНОЙ НАГРУЗКИ: положения запорного крана . Включение и выключение . Выключение в аварийной ситуации . Включение и выключение с дистанционного пульта . Включение и выключение при помощи таймера . Квитирование сообщений . Вентиляция распределительного шкафа . Очистка радиатора . Фильтровальный мат для охлаждающего воздуха . Техобслуживание воздушного фильтра . Техобслуживание двигателей . Проверка муфты сцепления . Проверка уровня охлаждающего масла . Сброс давления из машины . Доливка охлаждающего масла . Замена охлаждающего масла, маслоотделитель . Замена охлаждающего масла, масляный радиатор . Замена охлаждающего масла, блок компрессора . Замена охлаждающего масла, система рекуперации тепла . Замена масляного фильтра . Заменить сменный элемент маслоотделителя . Холодоосушитель . Проверить устройство отвода конденсата . Техобслуживание устройства отвода конденсата . Транспортировка вилочным погрузчиком . Транспортировка с помощью крана .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

6 32 37 38 39 39 40 40 41 42 46 47 48 51 54 56 57 59 63 64 65 67 68 69 70 71 80 81 82 84 85 86 88 89 91 94 96 96 97 99 100 101 102 103 116 117

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Таб. 1 Таб. 2 Таб. 3 Таб. 4 Таб. 5 Таб. 6 Таб. 7 Таб. 8 Таб. 9 Таб. 10 Таб. 11 Таб. 12 Таб. 13 Таб. 14 Таб. 15 Таб. 16 Таб. 17 Таб. 18 Таб. 19 Таб. 20 Таб. 21 Таб. 22 Таб. 23 Таб. 24 Таб. 25 Таб. 26 Таб. 27 Таб. 28 Таб. 29 Таб. 30 Таб. 31 Таб. 32 Таб. 33 Таб. 34 Таб. 35 Таб. 36 Таб. 37 Таб. 38 Таб. 39 Таб. 40 Таб. 41 Таб. 42 Таб. 43 Таб. 44 Таб. 45 Таб. 46 Таб. 47 Таб. 48 Таб. 49 Таб. 50 Таб. 51 Таб. 52 Таб. 53

Степени опасности и их значение (опасность для персонала) . Степени опасности и их значение (материальный ущерб) . Фирменная табличка . Опции . Вес машины . Температура . Окружающие условия . Вентиляция . Давление срабатывания предохранительного клапана (50Гц) . Давление срабатывания предохранительного клапана (60Гц) . Производительность (50 Гц) . Производительность (60 Гц) . Рекомендуемые охлаждающие масла . Рекомендуемые охлаждающие масла (для пищевой промышленности) . Рекомендуемые охлаждающие масла (машины для снежных пушек) . Количество заливаемого охлаждающего масла (опция K1) . Количество заливаемого охлаждающего масла (опция K2) . Количество заливаемого охлаждающего масла (опция K9) . Количество заливаемого охлаждающего масла (опция W1) . Количество заливаемого охлаждающего масла (опция W2) . Количество заливаемого охлаждающего масла (опция W3) . Двигатель компрессора (50Гц) . Двигатель компрессора (60Гц) . Двигатель вентилятора (опция K1) . Двигатель вентилятора (опция K2/K9; 50Гц) . Двигатель вентилятора (опция K2/K9; 60Гц) . Звуковое излучение [дБ(А)] . Характеристики подключения 200В/3/50Гц . Характеристики подключения 230В/3/50Гц . Характеристики подключения 400В/3/50Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Температура охлаждающей воды (ΔT=10K) . Температура охлаждающей воды (ΔT=30K) . Спецификация: Теплообменник (опция K2) . Качество охлаждающей воды . Температура охлаждающей воды (ΔT=10K) . Температура охлаждающей воды (ΔT=30K) . Спецификация: теплообменника (опция K9) . Качество охлаждающей воды . Тепловая мощность (опция W1) . Качество охлаждающей воды . Спецификация: Теплообменник (опции W2/W3) . Тепловая мощность (опции W2/W3) . Объемный поток/потеря давления (опция W2) . Объемный поток/потеря давления (опция W3) . Холодоосушитель: Πневмосистема . Холодоосушитель: Cистема циркуляции хладагента . Сроки технического освидетельствования в соответствии правил безопасной эксплуатации . Опасные зоны . Знаки безопасности .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

1 2 4 4 5 5 5 6 6 7 7 7 8 8 9 10 10 10 11 11 11 11 12 12 12 13 13 14 15 15 15 15 16 16 17 17 18 18 19 19 19 20 20 21 21 22 22 22 22 23 26 31 33

Таб. 54 Таб. 55 Таб. 56 Таб. 57 Таб. 58 Таб. 59 Таб. 60 Таб. 61 Таб. 62 Таб. 63 Таб. 64 Таб. 65 Таб. 66 Таб. 67 Таб. 68 Таб. 69 Таб. 70 Таб. 71

Энергосберегающие виды регулирования . 43 Рабочие режимы при виде регулирования ЧАСТИЧНАЯ НАГРУЗКА . 44 Виды регулирования холодоосушителя . 45 Кнопки . 46 Индикаторы . 47 RFID-считывающее устройство . 49 Ввод в эксплуатацию после длительного хранения/перерыва в работе . 61 Чек-лист проверки требований монтажа . 61 Регулирование ЧАСТИЧНОЙ НАГРУЗКИ: положения запорного крана . 64 Обозначение на машине . 69 Обозначение на дистанционном пульте . 69 Обозначение на машине . 70 Прочие неисправности и меры устранения . 73 Регулярные работы по техобслуживанию . 77 Охлаждающее масло: интервалы замен . 78 Регулярные профилактические работы . 79 Зарегистрированные работы по техническому обслуживанию . 104 Запасные части для техобслуживания машины . 105

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

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Порядок обращения с документом

Порядок обращения с документом Инструкция по эксплуатации является составной частью изделия. В ней описано состояние машины на момент поставки заводом-изготовителем. ➤ Храните инструкцию по эксплуатации в течение всего срока службы машины. ➤ Передавайте инструкцию по эксплуатации каждому последующему владельцу или по‐ льзователю. ➤ Обеспечьте внесение в инструкцию по эксплуатации всех изменений. ➤ Внесите данные фирменной таблички и индивидуальные особенности комплектации ма‐ шины в таблицу в разделе 2.

Дополнительные документы Вместе с инструкцией по эксплуатации Вы получите дополнительные документы: ■

Свидетельство о приемке/инструкция по эксплуатации ресивера

Декларация о соответствии требованиям действующих директив

Инструкция по пользованию SIGMA CONTROL 2

Отсутствующие документы могут быть заказаны на фирме KAESER. ➤ Проверьте комплектность документов и соблюдайте содержащиеся в них указания. ➤ При заказе дополнительных документов, просим непременно указать данные фирменной таблички.

Авторское право Данная инструкция по эксплуатация защищена авторскими правами. По вопросам относи‐ тельно применения и размножения документации обращайтесь к фирме KAESER. Мы охот‐ но окажем Вам содействие в отношении соответствующего использования информации.

Символы и условные обозначения ➤ Обратите внимание на символы и обозначения, приведенные в данной инструкции.

Указания по предупреждению Указания по предупреждению предупреждают о возможной опасности для персонала, воз‐ никшей в результате несоблюдения соответствующих мероприятий. Предупреждающие указания подразделены на три степени опасности, которые Вы можете распознать по сигнальному слову:

Предупреждает о непосред‐ В результате тяжелые телесные ственно угрожающей опасно‐ повреждения или смертельный исход сти

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Последствия при несоблюдении

Символы и условные обозначения

Последствия при несоблюдении

ПРЕДУПРЕЖДЕНИЕ Предупреждает о возможной Возможны тяжелые телесные повреж‐ угрожающей опасности дения или смертельный исход ОСТОРОЖНО Таб. 1

Предупреждает о возможной Возможны легкие телесные повреж‐ опасной ситуации дения

Степени опасности и их значение (опасность для персонала) Предупреждающие указания, находящиеся в начале раздела, распространяются на весь раздел и все его подразделы. Пример: ОПАСНО Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждающих указа‐ ний. Сигнальное слово «ОПАСНО» означает, что несоблюдение этих указаний может при‐ вести к тяжелым телесным повреждениям или смертельному исходу. ➤ Здесь описаны мероприятия, с помощью которых Вы можете защитить себя от опасности. Предупреждающие указания, распространяющиеся на подразделы или руководство к дей‐ ствию, приведены непосредственно в них и их очередность пронумерована. Пример: 1. ПРЕДУПРЕЖДЕНИЕ! Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждающих указаний. Сигнальное слово «ПРЕДУПРЕЖДЕНИЕ» означает, что несоблюдение этих указаний мо‐ жет привести к тяжелым телесным повреждениям или смертельному исходу. ➤ Здесь описаны мероприятия, с помощью которых Вы можете защитить себя от опас‐ ности. 2. Внимательно прочитать предупреждающие указания и всегда соблюдать их.

Предупреждения нанесения материального ущерба В отличии от предупреждающих указаний в данном случае речь не идет об опасности для персонала. Предупреждения о нанесении материального ущерба Вы можете распознать по сигнальному слову:

Сигнальное слово Значение

Последствия при несоблюдении

Возможен материальный ущерб

Предупреждает о возможной опасной ситуации

Степени опасности и их значение (материальный ущерб) Пример:

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Символы и условные обозначения

УКАЗАНИЕ Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждений. ➤ Здесь описаны мероприятия, с помощью которых можно предотвратить нанесение материального ущерба. ➤ Внимательно прочитать предупреждения и неукоснительно соблюдать их.

Дополнительные указания и символы Этот символ указывает на важную информацию.

Материал Обязательное условие

Здесь указаны данные о специальном инструменте, эксплуатационных материалах или за‐ пасных частях. Здесь описаны обязательные условия для осуществления каких-либо действий. В данном случае могут указываться меры безопасности, которые помогут Вам предотвра‐ тить возникновение опасных ситуаций.

➤ Этот символ указывает на руководство к действию, состоящее только из одного шага. Если действия совершаются посредством нескольких шагов, их очередность пронумеро‐ вана. Информация, касающаяся только одной опции, имеет буквенно-цифровое обозначение (например: Н1 означает, что этот раздел распространяется только на машины с возмож‐ ностью крепления опор к полу). Буквенно-цифровые обозначения, встречающиеся в дан‐ ной инструкции, пояснены в разделе 2.2. Информация о потенциальных проблемах обозначена с помощью вопросительного знака. Во вспомогательном тексте указывается причина . ➤ . и дается рекомендация по ее устранению. Этот символ указывает на важную информацию или мероприятия по охране окружаю‐ щей среды.

Здесь обращают Ваше внимание на последующее описание данной темы.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

2 Технические характеристики 2.1

Фирменная табличка На фирменной табличке Вы найдете основные технические данные и модель машины. Фирменная табличка находится снаружи машины: ■

➤ Укажите здесь данные фирменной таблички: Наименование

Винтовой компрессор Артикульный номер Серийный номер Год выпуска Номинальная мощность Номинальное число оборотов двигателя Максимальное избыточное рабочее давление Окружающая температура Таб. 3

Опции Перечень возможных опции приведен в таблице. ➤ Укажите дополнительную комплектацию в графе о наличии: Опция

Регулирование частичной нагрузки

Прикручивающиеся опоры машины

Водяное охлаждение (пластинчатый теплообменник)

Фильтровальный мат для охлаждающего воздуха

Водяное охлаждение (трубчатый теплообменник)

Электропитание холодоосушителя через транс‐ форматор

Подготовка для системы рекуперации тепла

Система рекуперации тепла ΔT=25 K

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Винтовой компрессор 9_9519 02 R

Система рекуперации тепла ΔT=55 K Таб. 4

Указанный вес является максимальным весом. Действительный вес машины зависит от ин‐ дивидуального оснащения. CSDX 140

Минимальная темпера‐ тура включения [°C]

Рабочая конечная тем‐ пература сжатия [°C]

Максимальная конечная температура сжатия (автоматическое защит‐ ное отключение) [°C]

Максимальная высота над уровнем моря в ме‐ сте установки* [м]

Допустимая окружаю‐ щая температура [°C]

Температура охлаждаю‐ щего воздуха [°C]

Температура всасывае‐ мого воздуха [°C]

* Установка в более высоких местах возможна только по согласованию с изготовителем Таб. 7

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Максимальная относительная влажность всасываемого воздуха T H

Температура всасываемого воздуха [°C] Максимальная относительная влажность всасываемого воздуха [%]

Вентиляция Указанные значения являются нормативными значениями, которые не допускается зани‐ жать. CSDX 140

Проем приточной вен‐ тиляции Z см. рисунок 14, [м2]

Вытяжной вентилятор для принудительной вентиляции: объемный поток [м3/ч] при 100 Па

Давление Максимальное избыточное рабочее давление: см. фирменную табличку Давление срабатывания предохранительного клапана при 50 Гц [бар]: Максимальное избыточ‐ ное рабочее давление [бар]

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Винтовой компрессор 9_9519 02 R

Максимальное избыточ‐ ное рабочее давление [бар]

Давление срабатывания предохранительного клапана (50Гц) Давление срабатывания предохранительного клапана при 60 Гц [бар]: Максимальное избыточ‐ ное рабочее давление [бар]

Давление срабатывания предохранительного клапана (60Гц)

Производительность Производительность [м3/мин] при частоте сети 50 Гц: Максимальное избыточ‐ ное рабочее давление [бар]

Производительность (50 Гц) Производительность [м3/мин] при частоте сети 60 Гц: Максимальное избыточ‐ ное рабочее давление [бар]

Рекомендуемые охлаждающие масла Марка залитого охлаждающего масла указана на резервуаре маслоотделителя рядом с за‐ ливным патрубком. Информацию, необходимую для заказа охлаждающего масла, Вы найдете в разделе 11.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Рекомендуемые охлаждающие масла

Охлаждающие масла общего назначения SIGMA FLUID MOL

Без содержания силикона, синтетическое масло

Стандартное масло для всех областей применения за исклю‐ чением пищевой про‐ мышленности.

Стандартное масло для всех областей применения за ис‐ ключением пищевой промы‐ шленности.

Стандартное масло для стран Восточной и Юго-Восточной Азии, возможно ис‐ пользование во всех областях за исключе‐ нием пищевой промы‐ шленности.

Особенно подходит для машин с низкой нагрузкой.

Не разрешается использо‐ вать в странах Восточной и Юго-Восточной Азии.

Особенно подходит для машин с высокой нагрузкой.

Разрешение на примене‐ ние

40/40/0/10 мин (D 1401; ASTM-тест)

Способность к — деэмульгиро‐ ванию при 54 °C Таб. 13

Особенно подходит для ма‐ шин с высокой нагрузкой.

Рекомендуемые охлаждающие масла Охлаждающие масла для пищевой промышленности SIGMA FLUID Описание

Область примене‐ Специально для машин используе‐ ния мых в областях, где сжатый воздух может соприкасаться с продуктами питания.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Специально для машин используе‐ мых в областях, где сжатый воздух может соприкасаться с продуктами питания.

Винтовой компрессор 9_9519 02 R

Рекомендуемые охлаждающие масла

USDA H–1, NSF Разрешено при производстве упа‐ ковки для пищевых продуктов, в мясо- и птицеперерабатывающей промышленности и других отраслях по переработке продуктов питания.

USDA H–1, NSF Разрешено при производстве упа‐ ковки для пищевых продуктов, в мясо- и птицеперерабатывающей промышленности и других отраслях по переработке продуктов питания.

Способность к деэмульгирова‐ нию при 54 °C

Рекомендуемые охлаждающие масла (для пищевой промышленности) Охлаждающие масла для эксплуатации со снежными пушками SIGMA FLUID PANOLIN HLP SYNTH 46 Описание

Насыщенный сложный эфир с присадками (без содержа‐ ния нефти) Согласно критерий OECD способно к биологическому раз‐ ложению

Специально для машин, предусмотренных для эксплуата‐ ции со снежными пушками.

Способность к деэмульгирова‐ нию при 54 °C

Рекомендуемые охлаждающие масла (машины для снежных пушек)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Количество заливаемого охлаждающего масла

Количество заливаемого охлаждающего масла Заливаемое количество варьируется в зависимости от опции системы рекуперации тепла. Для машин с опцией W1, W2 или W3 необходимо долить дополнительное количество охла‐ ждающего масла для системы рекуперации тепла.

Воздушное охлаждение CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 16 Опция K2

Количество заливаемого охлаждающего масла (опция K1) Водяное охлаждение (пластинчатый теплообменник) CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 17 Опция K9

Количество заливаемого охлаждающего масла (опция K2) Водяное охлаждение (трубчатый теплообменник) CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 18

Количество заливаемого охлаждающего масла (опция K9)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Система рекуперации тепла Количество доливаемого масла увеличивается на объем охлаждающего масла в теплооб‐ меннике и трубопроводах: CSDX 140

Дополнительное коли‐ чество заливаемого ма‐ сла [л]* * Укажите количество масла, заливаемого в Вашу систему рекуперации тепла Таб. 19

Количество заливаемого охлаждающего масла (опция W1)

Опция W2 Дополнительное коли‐ чество заливаемого ма‐ сла [л] Таб. 20

Количество заливаемого охлаждающего масла (опция W2)

Опция W3 Дополнительное коли‐ чество заливаемого ма‐ сла [л]

Количество заливаемого охлаждающего масла (опция W3)

Двигатель компрессора Частота сети: 50 Гц CSDX 140

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Номинальная мощ‐ ность [кВт]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 22

Двигатель компрессора (50Гц)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Частота сети: 1000 м CSDX 140

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Номинальная мощ‐ ность [кВт]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 23

Двигатель компрессора (60Гц)

Опция K1 Двигатель вентилятора CSDX 140

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 24

Двигатель вентилятора (опция K1)

Опция K2/K9 Двигатель вентилятора Частота сети: 50 Гц

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

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Винтовой компрессор 9_9519 02 R

Двигатель вентилятора (опция K2/K9; 50Гц) Частота сети: 1000 м CSDX 140

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

Двигатель вентилятора (опция K2/K9; 60Гц)

Звуковое излучение [дБ(А)] Частота сети

Уровень звукового давления согласно ISO 2151 и основополагающего стандарта ISO 9614-2, допустимая погрешность: ± 3 дБ(A) при максимальном избыточном рабочем да‐ влении * Опция K2/K9 Таб. 27

Электрическое питание Основные требования Машина сконструирована в соответствии условий электроснабжения согласно стандарта EN 60204-1 (IEC 60204-1), раздела 4.3. Если потребителем не установлены иные условия, необходимо соблюдать предельные зна‐ чения, описанные в данном стандарте. Кроме того, рекомендуем провести согласование между потребителем и поставщиком на ос‐ нове стандарта EN 60204-1, приложение B. Для электрического подключения машины необходима симметричная трехфазная сеть. В симметричной трехфазной сети напряжение и сдвиг фаз между отдельными фазами оди‐ наковы. Эксплуатация машины допускается только от трехфазной сети с системой заземления типа TN или TT. Не допускается подключение к сети с системой заземления типа IT без дополнительных ме‐ роприятий (контроля сопротивления изоляции и т.д.). Машина рассчитана для эксплуатации от сети электроснабжения внутри промышленных объектов, отделенной от общественной сети электроснабжения с помощью трансформатора или генератора. Кабель питания внутри шкафа должен быть проложен кратчайшим путем.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Характеристики электрического подключения

При необходимости подключения к машине внешних сенсоров или коммуникационных кабе‐ лей, использовать для этого экранированные кабели и кабельные вводы, отвечающие тре‐ бованиям ЭМС. Дополнительные требования Требования к трехфазной сети для машины, оснащенных: ■

с холодоосушителем с электропитанием через трансформатор

Подключение данной машины допускается только к трехфазной сети с системой заземления типа TN или TT с заземленной нулевой точкой при соединении «звездой». Не допускается подключение данной машины к трехфазной сети с заземленной фазой, так как это может привести к опасному перенапряжению. Не допускается подключение к сети с системой заземления типа IT без дополнительных ме‐ роприятий (контроля сопротивления изоляции, специального исполнения частотного преоб‐ разователя и т.д.). Дополнительная информация

На электрической схеме в разделе 13.4 указаны дополнительные сведения относительно электрического подключения.

Характеристики электрического подключения Нижеследующие сечения кабелей питания (медный многожильный кабель) и предохраните‐ ли (плавкий предохранитель, класс эксплуатации gL) рассчитаны согласно стандарта DIN VDE 0100-430 (IEC 60364-4-43 и IEC 60364-4-473) и DIN VDE 0298-4 для окружающей температуры 30 °C и способа прокладки C. ➤ При других условиях эксплуатации проверить сечение кабелей питания и привести в соответствие. К другим условиям эксплуатации относятся, например:

Частота сети: 50 Гц Номинальное напряжение: 200В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 200В/3/50Гц

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Характеристики электрического подключения

Номинальное напряжение: 230В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 230В/3/50Гц Номинальное напряжение: 400В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 400В/3/50Гц

Частота сети: 1000 м Номинальное напряжение: 230В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц Номинальное напряжение: 380В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Номинальное напряжение: 440В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц Номинальное напряжение: 460В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц

Опция K2/K9 Водяное охлаждение При возникновении утечки, охлаждающее масло может попасть в охлаждающую воду. ➤ Нагрев питьевой воды производить только посредством соответствующего теп‐ лообменника. При добавлении в охлаждающую воду средства против замерзания, изменяется удель‐ ная теплопроводность охлаждающей воды и необходимый объем потока. ➤ Для обеспечения безупречной работы системы охлаждения, обратитесь в автори‐ зованную сервисную службу KAESER. ➤ Для предотвращения сбоев в работе вследствие образование ржавчины, отложе‐ ний извести и загрязнении необходимо соблюдать указанные требования к охлаж‐ дающей воде Обязательным условием является проведение мероприятий по фильтрации и подго‐ товке охлаждающей воды. Адреса организаций, выполняющих анализ качества воды и поставляющих приборы для подготовки воды Вы можете получить, обратившись в фирму KAESER. Возможны следующие конструктивные варианты:

Опция К2: водяное охлаждение с пластинчатым теплообменником, раздел 2.15.1

Опция K9: водяное охлаждение с трубчатым теплообменником, раздел 2.15.2

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Открытая система охлаждения Примером открытой системы охлаждения может служить охлаждающий контур с открытой градирней, где охлаждающая вода остывает за счет испарения. Поскольку часть воды ис‐ паряется, она должна постоянно добавляться. Последствием испарения является концен‐ трация загрязняющих веществ в охлаждающей воде, загрязнение может усугубляться вследствие контакта воды с окружающим воздухом. При доливке охлаждающей воды сле‐ дует соблюдать требования, предъявляемые к охлаждающей воде. Закрытая система охлаждения В закрытой системе охлаждения охлаждающая вода не контактирует с атмосферным возду‐ хом. Поэтому исключены попадание загрязнений из воздуха и обогащение кислородом. Проточная система охлаждения Проточная система охлаждения это открытая система охлаждения. Водопроводная вода, во‐ да из подземных источников и открытых водоемов проходит через систему охлаждения один раз. Дополнительная информация

Направление потока, размеры и расположение соединительного штуцера Вы найдете на га‐ баритном чертеже в разделе 13.3.

Опция K2 Водяное охлаждение (пластинчатый теплообменник) Первичный контур теплообменника подключен к машине. Приведенные данные отно‐ сятся к вторичному контуру теплообменника.

Технические данные Повышение температуры охлаждающей воды на 10 K:

Максимально допусти‐ мая температура на входе [°C]

Температура охлаждающей воды (ΔT=10K) Повышение температуры охлаждающей воды на 30 K:

Максимально допусти‐ мая температура на входе [°C]

Температура охлаждающей воды (ΔT=30K)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Спецификация теплообменника: CSDX 140

Максимальное избыточ‐ ное рабочее давление [бар]

Максимально допусти‐ мая температура на вы‐ ходе [°C]

Максимальный объем‐ ный поток [м3/ч]

Непригодные охла‐ ждающие средства

Соленая вода Использование водных растворов разрешено только по согласова‐ нию с фирмой KAESER

Спецификация: Теплообменник (опция K2)

Качество охлаждающей воды Свойства/содержащиеся вещества

Источник