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KAESER Manuals
Compressor
BSD 40
Service manual
KAESER BSD 40 Service Manual
Screw compressor
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
1 Regarding this Document Using the Document
Further Documents
Copyright
Symbols and Identification
Warnings
Other Instructions and Symbols
Tab. 1 the Levels of Danger and Their Meaning
2 Technical Data Nameplate
Options
Tab. 2 Nameplate
Weight
Temperature
Ambient Conditions
Tab. 3 Options
Tab. 4 Machine Weight
Tab. 5 Temperature
Tab. 6 Ambient Conditions
Ventilation
Pressure
Fig. 1 Maximum Relative Humidity
Tab. 7 Ventilation
Tab. 8 Safety Relief Valve Setting
Delivery
Cooling Oil Recommendation
Basic Information
KAESER Lubricants
Tab. 9 Delivery
Cooling Oil Charge
Tab. 10 Cooling Oil Charge (Option K1)
Tab. 11 Cooling Oil Charge (Option K2)
Motors and Power
Drive Motor
Fan Motor
Tab. 12 Cooling Oil Charge (Option W1)
Tab. 13 Cooling Oil Charge (Option W2)
Tab. 14 Cooling Oil Charge (Option W3)
Tab. 15 Drive Motor
Fan Motor
Sound Pressure Level
Power Supply
Tab. 16 Fan Motor (Option K1)
Tab. 17 Fan Motor (Option K2)
Tab. 18 Sound Pressure Level
Power Supply Specifications
Tab. 19 Supply 208V/3/60Hz
Tab. 20 Connection Details 230V/3/60Hz
Water-Cooling
Design Data
Tab. 21 Connection Details 380V/3/60Hz
Tab. 22 Connection Details 460V/3/60Hz
Tab. 23 Supply 575V/3/60Hz
Cooling Water Quality
Tab. 24 Cooling Water Temperature (ΔT=20°F)
Tab. 25 Cooling Water Temperature (ΔT=50°F)
Tab. 26 Cooler Specification (Option K2)
Heat Recovery
Prepared for External Heat Recovery
Internal Heat Recovery
Tab. 27 Cooling Water Quality
3 Safety and Responsibility Basic Information
Specified Use
Improper Use
User's Responsibilities
Observe Statutory and Universally Accepted Regulations
Qualified Personnel
Adhere to Inspection Schedules and Accident Prevention Regulations
Dangers
Safely Dealing with Sources of Danger
Safe Machine Operation
Organizational Measures
Danger Areas
Safety Devices
Safety Signs
Tab. 34 Danger Areas
Fig. 2 Location of Safety Signs
Emergencies
Correct Fire Fighting
Tab. 35 Safety Signs
Remove any Cooling Oil from Your Person
Warranty
Environmental Protection
4 Design and Function
Enclosure
Functional Description of the Machine
Fig. 3 Enclosure Overview
Floating Relay Contacts
Fig. 4 Machine Layout
Options
Machine Mountings
Cooling Air Filter Mat
Water-Cooling
Fig. 5 Machine Mountings
Fig. 6 Cooling Air Filter Mat (Option K3)
Heat Recovery
Fig. 7 Water-Cooling (Option K2)
Operating Modes and Control Modes
Operating Modes
Control Modes
Fig. 8 Internal Heat Recovery (Option W2/W3)
Tab. 36 Energy-Efficient Control Modes
Safety Devices
SIGMA CONTROL Keys and Indicators
Fig. 9 Keys
Tab. 37 Operating Modes under MODULATING Control
Fig. 10 Indicators
Tab. 38 Keys
Tab. 39 Indicators
5 Installation and Operating Conditions
Safety
Installation Conditions
Determining Location and Clearances
Ensure Adequate Ventilation
Exhaust Duct Design
Fig. 11 Recommended Machine Placement and Dimensions [MM]
Using the Compressor to Supply a Compressed Air System
6 Installation Safety
Reporting Transport Damage
Making the Compressed Air Connection
Making the Power Supply Connection
Fig. 12 Compressed Air Connection
Options
Anchoring the Machine
Connecting the Cooling Water
Fig. 13 Connecting the Cooling Water
Connecting the Heat Recovery System
Fig. 14 Connecting the Heat Recovery System
7 Initial Start-Up Safety
To be Noted before Commissioning
Checking Installation and Operating Conditions
Tab. 40 Re-Commissioning after Storage
Setting the Overload Protection Cut-Out
Setting the Motor Overload Protection Switch
Filling Cooling Oil into the Airend
Tab. 41 Installation and Operating Conditions Checklist
Checking Direction of Rotation
Fig. 15 Inlet Valve Filling Port
Fig. 16 Coupling
Starting the Machine for the First Time
Setting the Setpoint Pressure
Changing the Display Language
Fig. 17 Label: Changing the Display Language
8 Operation
Switching on and off
Switching on
Shutdown
Fig. 18 Switching on and off
Switching off in an Emergency and Switching on Again
Switching on and off from a Remote Control Center
Fig. 19 Switching off in an Emergency
Switching on and off with the Clock
Fig. 20 Switching on and off from a Remote Control Center
Tab. 42 Machine Identification
Tab. 43 Remote Control Identification
Acknowledging Alarm and Warning Messages
Fig. 21 Switching on and off with the Clock
Tab. 44 Machine Identification
Fig. 22 Acknowledging Messages
9 Fault Recognition and Rectification
Basic Information
Alarm Messages (Machine Stop)
Warning Messages (Yellow LED Lights)
Other Faults
Tab. 46 Warning Messages
Tab. 47 Other Faults and Actions
10 1 Maintenance
Safety
Maintenance Schedule
Logging Maintenance Work
Resetting Maintenance Interval Counters
Regular Maintenance Tasks
Cooling Oil Changing Interval
Tab. 48 Regular Maintenance Tasks
Regular Service Tasks
Cleaning or Renewing the Cooling Air Filter Mat
Cleaning or Replacing the Control Cabinet Filter Mats
Fig. 23 Cooling Air Filter Mat
Cooler Maintenance
Fig. 24 Control Cabinet Ventilation Grill
Water-Cooling Maintenance
Fig. 25 Cleaning the Cooler
Maintain the Heat Recovery System
External Heat Recovery System
Internal Heat Recovery
Air Filter Maintenance
Motor Maintenance
Fig. 26 Air Filter Maintenance
Checking the Coupling
Fig. 27 Drive Motor Maintenance
Checking the Safety Relief Valve
Fig. 28 Checking the Coupling
Checking the Overheating Safety Shutdown Function
Checking the Cooling Oil Level
Venting the Machine (Depressurizing)
Fig. 29 Checking the Cooling Oil Level
Fig. 30 Venting the Machine
Topping up the Cooling Oil
Venting the Machine (Depressurizing)
Fig. 31 Topping up the Cooling Oil
Top up with Cooling Oil and Test Run
Changing the Cooling Oil
Fig. 32 Changing the Cooling Oil, Oil Separator Tank
Fig. 33 Changing the Cooling Oil, Oil Cooler
Fig. 34 Changing the Cooling Oil, Airend
Fig. 35 Changing the Cooling Oil, Oil Tank
Changing the Oil Filter
Fig. 36 Changing the Cooling Oil, Heat Recovery System
Changing the Oil Separator Cartridge
Fig. 37 Changing the Oil Filter
Fig. 38 Changing the Oil Separator Cartridge
Document Maintenance and Service Work
Tab. 51 Logged Maintenance Tasks
11 Spares, Operating Materials, Service
Note the Nameplate
Ordering Consumable Parts and Operating Fluids/Materials
Kaeser Air Service
Tab. 52 Consumable Parts
Service Addresses
Spare Parts for Service and Repair
12 Decommissioning, Storage and Transport
Putting out of Operation
Packing
Storage
Transporting
Safety
Transporting with a Forklift
Transporting with a Crane
Fig. 39 Transporting with a Forklift
Disposal
Fig. 40 Transporting with a Crane
13 Annex
Pipeline and Instrument Flow Diagram (P+I Diagram)
Pipe and Instrument Flow Diagram (P+I Diagram): MODULATING Control Mode
Dimensional Drawing
Electrical Diagram
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