Page 1 Service Manual Screw Compressor 9_5708 08 USE...
Page 2 Original instructions /KKW/SBSD 1.02 en 01 SBA-SCHRAUBEN-SC /KKW/SSC 1.04 01...
Page 3: Table Of Contents
Pressure ........................... Delivery ..........................Cooling Oil Recommendation ..................2.9.1 Basic Information ....................2.9.2 KAESER Lubricants .................... 2.10 Cooling oil charge ......................2.11 Motors and Power ......................2.11.1 Drive motor ......................2.11.2 Fan motor ......................2.11.3 Fan motor ......................2.12 Sound Pressure Level ......................
Page 4 Contents Design and Function Enclosure ......................... Functional Description of the Machine ................Floating relay contacts ..................... Options ..........................4.4.1 Machine mountings ..................... 4.4.2 Cooling air filter mat .................... 4.4.3 Water-cooling ...................... 4.4.4 Heat recovery ..................... Operating modes and control modes ................4.5.1 Operating modes ....................
Page 5 10.19 Document maintenance and service work............... Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Ordering consumable parts and operating fluids/materials ..........11.3 KAESER AIR SERVICE ....................11.4 Service Addresses ......................11.5 Spare Parts for Service and Repair ................. Decommissioning, Storage and Transport 12.1 Putting Out of Operation ....................
Page 6 Contents Service Manual Screw Compressor 9_5708 08 USE...
Page 7 List of Illustrations Fig. 1 Maximum relative humidity ......................Fig. 2 Location of safety signs ......................Fig. 3 Enclosure overview ........................Fig. 4 Machine layout ........................... Fig. 5 Machine mountings ........................Fig. 6 Cooling air filter mat (option K3) ....................Fig.
Page 8 List of Illustrations Service Manual Screw Compressor 9_5708 08 USE...
Page 9 List of Tables Tab. 1 The levels of danger and their meaning ..................Tab. 2 Nameplate ..........................Tab. 3 Options ............................Tab. 4 Machine weight .......................... Tab. 5 Temperature ..........................Tab. 6 Ambient Conditions ........................Tab. 7 Ventilation ........................... Tab. 8 Safety relief valve setting ......................
Page 10 List of Tables Service Manual Screw Compressor viii 9_5708 08 USE...
Page 11: Regarding This Document Using The Document
➤ Make sure you give the data from the nameplate when ordering documents. Copyright This service manual is copyright protected. Queries regarding use or duplication of the documentation should be referred to KAESER. Correct use of information will be fully supported. Symbols and Identification 1.4.1 Warnings Warning notices indicate three levels of danger signified by the signal word.
Page 12: Other Instructions And Symbols
Regarding this Document Symbols and Identification Signal word Meaning Consequences of non-observance WARNING Warns of possible danger Death or serious injury are possible CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible tion Tab. 1 The levels of danger and their meaning 1.4.2 Other instructions and symbols...
Page 13: Technical Data Nameplate
Technical Data Nameplate 2 Technical Data Nameplate The model designation and important technical information are given on the machine's nameplate. The nameplate is located on the outside of the machine: ■ above the cooler ■ on the rear of the machine. ➤...
Page 14: Weight
Heat recovery ΔT=45 K Heat recovery ΔT=55 K Tab. 3 Options Weight The weight given is the maximum. Actual weights of individual machines are dependent on equipment fitted. BSD 40 BSD 50 BSD 60 Weight [lb] 2270 2350 2540 Tab. 4...
Page 15: Ventilation
Technical Data Ventilation Fig. 1 Maximum relative humidity Inlet air temperature [°F] Maximum relative humidity of inlet air [%] Ventilation The values given are minimum guide values. BSD 40 BSD 50 BSD 60 Inlet aperture see fig‐ 8.6/2.2* 10.8/2.2* 12.9/2.2* ure 11 [sq.ft.]...
Page 16: Delivery
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐ pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire- resistant fluid.
Page 17: Cooling Oil Charge
PAO and diester fluids. ■ S–460 lubricant is recommended for compressors operating in ambient temperatures between 40 °F and 105 °F. Specialty KAESER LUBRICANTS: ■ S–680 lubricant may be used when ambient temperatures are always between 70 °F and 105 °F. ■...
Page 18: Motors And Power
Motors and Power Option W1/W2/W3 Heat recovery Option W1 The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines: BSD 40 BSD 50 BSD 60 Additional charge vol‐ ume [quart]* * Enter the volume required by your heat recovery system.
Page 19: Fan Motor
Technical Data 2.12 Sound Pressure Level BSD 40 BSD 50 BSD 60 Rated speed [rpm] 1120 1120 1120 Enclosure protection TEFC TEFC TEFC h = operating hours Tab. 16 Fan motor (option K1) 2.11.3 Option K2 Fan motor BSD 40...
Page 20: Power Supply Specifications
250.122 will point out the ”minimum size”, however, we recommend a ground conductor the same size as the power leads, if local codes allow. Rated power supply 208V ±10%, 3-ph, 60Hz BSD 40 BSD 50 BSD 60 Pre-fuse [A] 175/150* —...
Page 21: Water-Cooling
Technical Data 2.15 Water-cooling Rated power supply 380V±10%/3/60Hz BSD 40 BSD 50 BSD 60 Pre-fuse [A] 150/125* Supply 4x AWG1 4x AWG1**/ 4x AWG1/0** AWG1/0** * Consumption [A] 66/64* 81/79* 100/98* * Option K2 ** 75 °C Tab. 21 Connection details 380V/3/60Hz Rated power supply 460V±10%/3/60Hz...
Page 22: Cooling Water Quality
➤ Consult authorized KAESER Service representative to ensure optimum cooling-system performance. It is imperative that measures for cooling water treatment and filtration are implemented. KAESER can provide the names of companies specializing in cooling water analysis and the supply of suitable treatment plant. Characteristics/content...
Page 23: Heat Recovery
The quality of the heat transfer medium and its required flow rate depend on the type of heat exchanger used. Maximum permissible pressure loss in the cooling oil circuit: 8.7 psi. Maximum heat capacity BSD 40 BSD 50 BSD 60 available* [kW] 27.0...
Page 24 Technical Data 2.16 Heat recovery ➤ Consult KAESER Service if you wish to use a different heat-receiving medium. Water quality specification Characteristics/content Value pH value 7.5–9 Total hardness [°dH] 4.0–8.5 Chloride (Cl) [mg/l] <150 Free chlorine gas (Cl ) [mg/l] <1...
Page 25 Technical Data 2.16 Heat recovery Heat capacity Maximum heat capacity BSD 40 BSD 50 BSD 60 available* [kW] 27.0 33.3 40.8 [MJ/h] [kcal/h] 23216 28616 35082 * With the combination valve set to open at 176 °F. Tab. 31 Heat capacity (option W2/W3) Option W2 Flow rate for heating from 113 °F to 158 °F (equivalent to ΔT = 45F)
Page 26: Safety And Responsibility Basic Information
Safety and Responsibility Basic Information 3 Safety and Responsibility Basic Information The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ Danger to life and limb of the operator or third parties. ■...
Page 27: Qualified Personnel
Safety and Responsibility Dangers 3.4.2 Qualified personnel These are people who, by virtue of their training, knowledge and experience as well as their knowl‐ edge of relevant regulations can assess the work to be done and recognize the possible dangers involved.
Page 28: Safely Dealing With Sources Of Danger
Safety and Responsibility Dangers 3.5.1 Safely Dealing with Sources of Danger Information concerning the various forms of danger that can arise during machine operation are found here. Electricity ➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a qualified and authorized electrician to carry out work on electrical equipment according to elec‐...
Page 29 ➤ Do not eat or drink while handling cooling and lubricating fluids. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts ➤ Use only spare parts approved by the manufacturer for use in this machine.
Page 30: Safe Machine Operation
Safety and Responsibility Dangers 3.5.2 Safe Machine Operation Information on safe conduct when handling the machine is found here. Transport ➤ Use suitable lifting gear that conforms to local safety regulations. ➤ Allow transport only by personnel trained in the safe movement of goods. ➤...
Page 31: Safety Devices
Safety and Responsibility Safety Devices Activity Danger area Authorized personnel Transport Within a 10 ft radius of the machine. Installation personnel for transport preparation. No personnel during transport. Beneath the lifted machine. No personnel! Installation Within the machine. Installation personnel Within 3 ft radius of the machine and its supply cables.
Page 32: Fig. 2 Location Of Safety Signs
Safety and Responsibility Safety Signs Fig. 2 Location of safety signs Item Symbol Meaning Danger of fatal injury from touching electrically live components! ➤ Switch off and lock out the supply disconnecting device and check that no voltage is present. Machine starts automatically! Severe injury could result from rotating components, electrical voltage and air pres‐...
Page 33: Emergencies
Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded! ➤ Do not open or dismantle the valve. ➤ Call for authorized KAESER Service representative if a fault occurs. Serious injury or death can result from loosening or opening component under pres‐ sure! ➤...
Page 34: Remove Any Cooling Oil From Your Person
■ 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. 3.10 Environmental Protection ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐...
Page 35: Design And Function
Design and Function Enclosure 4 Design and Function Enclosure Fig. 3 Enclosure overview Control cabinet door Latch Panel (removable) The enclosure, when closed, serves various functions: ■ Sound insulation ■ Protection against contact with components ■ Cooling air flow The enclosure is not suitable for the following uses: ■...
Page 36: Floating Relay Contacts
Design and Function Floating relay contacts Fig. 4 Machine layout Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Drive motor Air filter Oil filter Oil/air cooler Airend Ambient air is cleaned as it is drawn in through the filter The air is then compressed in the airend The airend is driven by an electric motor Cooling oil is injected into the airend.
Page 37: Options
Design and Function Options Options The options available for your machine are described below. 4.4.1 Option H1 Machine mountings These mountings allow the machine to be anchored firmly to the floor. Fig. 5 Machine mountings 4.4.2 Option K3 Cooling air filter mat The mat filters the cooling air and keeps the cooler surface clean.
Page 38: Heat Recovery
Working elements are marked with their opening temperature [°C]. If the cooling oil temperature is too low, condensate can form and damage the machine. ➤ Consult KAESER Service on components and layout to ensure a fully functioning cooling and heat recovery system.
Page 39: Operating Modes And Control Modes
The load and power consumption of the drive motor rises and falls with the air demand. The regulating valve is factory set. The setting should not be changed without consultation with KAESER SERVICE. 4.5.2 Control modes In order to maintain system pressure between the set minimum and maximum values and to com‐...
Page 40: Tab. 36 Energy-Efficient Control Modes
Design and Function Operating modes and control modes ■ VARIO Option C1 ■ MODULATING control Energy-efficient control modes for various applications: Application Recommended control mode Compressed air station with one machine or several machines with compa‐ VARIO rable delivery Machine for peak load in a compressed air station DUAL Machine for intermediate load in a compressed air station VARIO...
Page 41: Safety Devices
Design and Function Safety Devices Compressed air demand Operating modes falls MODULATING IDLE STANDSTILL Tab. 37 Operating modes under MODULATING control Safety Devices The following safety devices are provided and may not be modified in any way. ■ EMERGENCY STOP button: The EMERGENCY STOP button shuts down the machine immediately.
Page 42: Fig. 10 Indicators
Design and Function SIGMA CONTROL Keys and Indicators Item Description Function «UP» Scrolls up the menu options. Increases a parameter value. «escape» Returns to the next higher menu option level. Exits the edit mode without saving. Returns to the main menu when held down at least 10 seconds. «enter»...
Page 43: Tab. 39 Indicators
Design and Function SIGMA CONTROL Keys and Indicators Item Description Function IDLE Lights green when the compressor is running in IDLE. Flashes when the «LOAD/IDLE» toggle key is pressed. Machine ON Lights green when the machine switched on. Clock The LED lights when the machine is in clock control. Remote control The LED lights when the machine is in remote control.
Page 44: Installation And Operating Conditions
The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be kept to. Precondition The floor must be level, firm and capable of bearing the weight of the machine.
Page 45: Ensure Adequate Ventilation
Installation and Operating Conditions Installation conditions Fig. 11 Recommended machine placement and dimensions [mm] Exhaust fan Exhaust air duct Air inlet aperture CAUTION Ambient temperature too low! Frozen condensate and highly viscous cooling oil can cause damage when starting the machine. ➤...
Page 46: Using The Compressor To Supply A Compressed Air System
Installation and Operating Conditions Using the Compressor to Supply A Compressed Air System. ➤ Consult the KAESER service representative before deciding on: ■ the design of the exhaust air ducting ■ the intersection between the machine and the exhaust air duct ■...
Page 47: Installation Safety
Installation Safety 6 Installation Safety The following instructions must be followed for safe installation. Warning instructions are always given before a potentially dangerous action. Basic Safety Instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2. Installation work may only be carried out by authorized personnel. 3.
Page 48: Making The Power Supply Connection
Installation Making the Power Supply Connection Fig. 12 Compressed air connection Axial compensator or hose Shut-off valve WARNING Serious injury or death can result from loosening or opening components under pressure. ➤ Vent all pressurized components and chambers completely. 1. A shut off valve must be installed by the user in the connection line. 2.
Page 49: Options
Individual machines may not receive an adequate flow under this system. Breakdowns are the result. ➤ KAESER can advise on how to ensure the cooling water supply via suitable control valves. Fig. 13 Connecting the cooling water...
Page 50: Connecting The Heat Recovery System
An unsuitable heat exchanger or incorrect installation may adversely impact the cooling oil cir‐ cuit within the compressor. Damage to the machine will follow. ➤ Consult with KAESER on a suitable heat exchanger and have an authorized KAESER Service do the installation.
Page 51: Fig. 14 Connecting The Heat Recovery System
Installation Options 6.5.3.2 Option W2/W3 Connecting the internal heat recovery system Connecting the internal heat recovery system Fig. 14 Connecting the heat recovery system Outlet Connection port with plug Inlet Pressure relief valve Shut-off valve 1. The user is to provide the following fittings: ■...
Page 52: Initial Start-Up Safety
Initial Start-up Safety 7 Initial Start-up Safety The following instructions must be followed for safe machine commissioning. Warning instructions are always given before a potentially dangerous action. Basic safety instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2.
Page 53: Checking Installation And Operating Conditions
➤ Change the oil filter. ➤ Change the oil separator cartridge. ➤ Change the cooling oil. ➤ Have the motor bearings checked by an authorized KAESER Service repre‐ sentative. 36 months ➤ Have the overall technical condition checked by an authorized KAESER Ser‐...
Page 54: Setting The Overload Protection Cut-Out
➤ Check the overload protection cut-out setting. The overload protection cut-out shuts the machine down despite being correctly set? ➤ Contact KAESER Service. Setting the motor overload protection switch Electrical diagram in chapter 13.4 gives the setting values for the motor overload protection switch.
Page 55: Checking Direction Of Rotation
Initial Start-up Checking direction of rotation Fig. 15 Inlet valve filling port Remove screw plug Inlet valve 1. Unscrew the filler plug from the inlet valve. 2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug. Fig.
Page 56: Starting The Machine For The First Time
Initial Start-up Starting the machine for the first time Starting the machine for the first time Precondition No one is working on the machine, all access doors are closed, all removable panels in place and secured. 1. Open the shut-off valve to the compressed air system. 2.
Page 57: Fig. 17 Label: Changing The Display Language
Initial Start-up 7.10 Changing the display language Fig. 17 Label: Changing the display language If required: Press «Enter» to enter language selection. Unlatch the EMERGENCY STOP button. Press the «UP» or «DOWN» keys as often If required: as necessary to reach the required lan‐ Acknowledge alarm message.
Page 58: Operation
Operation Switching On and Off 8 Operation Switching On and Off Always switch the machine on with the «ON» key and off with the «OFF» key. The power supply disconnecting device has been installed by the user. Fig. 18 Switching on and off Machine ON (green) Key «OFF»...
Page 59: Switching Off In An Emergency And Switching On Again
Operation Switching Off in an Emergency and Switching On again 3. Switch off and lock out the power supply disconnecting device. Controller ON LED extin‐ The machine is switched off and isolated from the power supply. The guishes. Switching Off in an Emergency and Switching On again The EMERGENCY STOP pushbutton is located below the control panel.
Page 60: Switching On And Off With The Clock
Operation Switching on and off with the clock Fig. 20 Switching on and off from a remote control center «Remote control» key Remote control LED 1. Attach an easily seen notice to the machine that warns of remote operation. Remote control: danger of unexpected starting! ➤...
Page 61: Acknowledging Alarm And Warning Messages
Operation Acknowledging alarm and warning messages Fig. 21 Switching on and off with the clock «Clock» key Clock LED 1. Attach an easily seen notice warning of time-controlled operation: Clock control: danger of unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine.
Page 62: Fig. 22 Acknowledging Messages
Operation Acknowledging alarm and warning messages Fig. 22 Acknowledging messages Warning LED (yellow) Alarm LED (red) «Acknowledge» key Alarm message alarm flashes. An alarm shuts the machine down automatically. The red LED The last line in the display shows the actual fault causing the alarm. Precondition The fault has been rectified ➤...
Page 63: Fault Recognition And Rectification
The messages valid for your machine are dependant on the controller and individual equipment. 1. Do not attempt fault removal measures other than those given in this manual. 2. In all other cases: have the fault rectified by an authorized KAESER Service representative agent. Alarm messages (machine stop) Message...
Page 64 2 ext. message 3 ext. message 4 ext. message 5 Frequency converter faulty. Call KAESER Service. back press. run Drive belts or coupling broken. Drive belts: Replace drive belts. Coupling: Call KAESER Service.
Page 65 M2 I⇞ Overload shut-down of the first fan mo‐ Investigate cause of shut-down. tor. Reset overload protection cut-out. Call KAESER Service. fan M3 I⇞ Overload shut-down of the second fan Investigate cause of shut-down. motor. Reset overload protection cut-out.
Page 66: Warning Messages (Yellow Led Lights)
Control cabinet: Check filter mats and fan. softstart Fault in the soft start equipment. Call KAESER Service. start T⇟ Airend discharge temperature (ADT) Keep ambient conditions within speci‐ too low. fied limits. Ambient temperature <+37°F...
Page 67 Check maximum cable length and screen‐ ing. 1 master and 1 slave configured. error: SMS SMS can not be sent. Call KAESER Service. ext. message 0 Customer specific: Carry out maintenance on connected com‐ ext. message 1 Connected component initiates a ponent.
Page 68 The maintenance interval for check‐ Have the motor bearings checked by an au‐ ing the compressor drive motor thorized KAESER Service Technician. bearings has expired. ext.load signal? Uncertain external load signal: Check settings of the external controller.
Page 69 Re-tension drive belts. blt.coup.insp.h⇞ The belts/coupling change interval Drive belts: has expired. Check drive belts. Coupling: Call KAESER Service. start T↓ The airend temperature is too low (< Keep ambient conditions within specified +37 °F). limits. start T↓↓ The airend temperature is too low Keep ambient conditions within specified (<14 °F) for the machine to be op‐...
Page 70: Other Faults
Warning messages Other Faults Fault Possible cause Remedy Machine runs but produces no Inlet valve not opening or only Call authorized KAESER Ser‐ compressed air. opening partially. vice representative. Venting valve not closing. Call authorized KAESER Ser‐ vice representative. Leaks in the pressure system.
Page 71: Tab. 47 Other Faults And Actions
Oil cooler leaking. Call authorized KAESER Ser‐ vice representative. Leaking joints. Tighten joints. Replace seals. Cooling oil consumption too Unsuitable oil is being used.
Page 72: 10.1 Maintenance
Maintenance 10.1 Safety 10 Maintenance 10.1 Safety The following instructions must be followed for safe machine maintenance. Warning instructions are always given before a potentially dangerous action. Basic safety instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2.
Page 73: Maintenance Schedule
Maintenance 10.2 Maintenance schedule 10.2 Maintenance schedule 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■ high temperatures ■ much dust ■...
Page 74: Cooling Oil Changing Interval
Machine utilization and ambient conditions are important criteria for the number and length of the change intervals. Authorized KAESER Service representative will support you in determining appropriate inter‐ vals and provide information on the possibilities of oil analysis. ➤ Please observe national regulations regarding the use of cooling oil in oil-injected screw com‐...
Page 75: Regular Service Tasks
10.2.5 Regular service tasks The table below lists necessary service tasks. ➤ Only an authorized KAESER Service Technician should carry out service work. ➤ Have service tasks carried out punctually taking ambient and operating conditions into account. Interval Service task Up to 12,000 h Have the valves checked.
Page 76: Cleaning Or Replacing The Control Cabinet Filter Mats
Maintenance 10.4 Cleaning or Replacing the Control Cabinet Filter Mats Fig. 23 Cooling air filter mat Cooling air filter mat Retaining frame Fixing Removal 1. Open the fixing by turning 90° counter clockwise with a screwdriver. 2. Remove the frame Cleaning ➤...
Page 77: Cooler Maintenance
Maintenance 10.5 Cooler Maintenance Fig. 24 Control cabinet ventilation grill Ventilation grill Filter mat 1. Carefully remove the ventilation grill and take out the filter mat 2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm water and household detergent.
Page 78: Water-Cooling Maintenance
➤ Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt. The air and oil coolers can no longer be properly cleaned? ➤ Heavy and stubborn contamination should be removed by a KAESER Service representa‐ tive.
Page 79: Maintain The Heat Recovery System
10.7 Maintain the heat recovery system 1. Check the cooler visually for leaks. 2. Have an authorized KAESER Service representative check the cooler for internal leaks at least once a year. Cleaning ➤ An authorized KAESER Service representative should clean the cooler when the airend dis‐...
Page 80: Motor Maintenance
Maintenance 10.9 Motor Maintenance Fig. 26 Air filter maintenance Cover Air filter element Opening the air filter housing 1. Unscrew the nuts and lift out the cover together with the air filter element 2. Unscrew the nut and remove the filter element. Cleaning the air filter element by tapping Renew the filter element at the latest after it has been cleaned 5 times.
Page 81: Checking The Coupling
Fan motor ➤ Have the motor bearings checked by a KAESER Service representative. Option K2 Fan motor ➤ Have the fan motor bearings checked by a KAESER Service representative during the course of a visit. 10.10 Checking the Coupling A defective coupling is recognizable by: ■...
Page 82: Checking The Safety Relief Valve
3. Refit the safety screen. 4. Close all access doors and replace all enclosure panels. Does the coupling have cracks or color changes? ➤ Have a damaged coupling changed by an authorized KAESER Service representative. 10.11 Checking the Safety Relief Valve In order to check the safety relief valve, the machine's working pressure is raised above the blowoff pressure of the valve.
Page 83: Checking The Overheating Safety Shutdown Function
The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F. ➤ Check the safety shutdown function as described in the SIGMA CONTROL manual. The machine does not shut down? ➤ Have the safety shutdown function checked by an authorized KAESER Service represen‐ tative. 10.13...
Page 84: Venting The Machine (Depressurizing)
Maintenance 10.14 Venting the machine (depressurizing) Fig. 29 Checking the cooling oil level Minimum oil level Maximum oil level Optimum level WARNING Danger of burning from hot surfaces! ➤ Wear long-sleeved clothing and protective gloves. ➤ Check the oil level with machine running. Result Top up when the indicator shows minimum level.
Page 85: Fig. 30 Venting The Machine
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an authorized KAESER Service representative. Vent air manually from the air cooler. After shutting down the compressor and venting the oil separator tank, there is still pressure on the machine from the compressed air system or in the section from the shut-off valve to the minimum pressure/check valve.
Page 86: Topping Up The Cooling Oil
Maintenance 10.15 Topping up the Cooling Oil 2. Slowly open the shut-off valve to release pressure. 3. Withdraw the male hose fitting and close the shut-off valve 10.15 Topping up the Cooling Oil The machine must be isolated from the compressed air system and completely vented before undertaking any work on the pressure system.
Page 87: Top Up With Cooling Oil And Test Run
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an authorized KAESER Service representative. Vent air manually from the air cooler After shutting down the compressor and venting the oil separator tank, there is still pressure on the machine from the compressed air system or in the section from the shut-off valve to the minimum pressure/check valve.
Page 88: Changing The Cooling Oil
Internal heat recovery system (option W1/W2/W3) ➤ Always change the oil filter and oil separator cartridge when changing the oil. ➤ Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to adjust the airend discharge temperature to suit operating conditions.
Page 89: Fig. 32 Changing The Cooling Oil, Oil Separator Tank
Maintenance 10.16 Changing the cooling oil Fig. 32 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Shut-off valve open Pressure gauge Shut-off valve closed Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drain) Cooling oil level indicator Shut-off valve (venting line)
Page 90: Fig. 33 Changing The Cooling Oil, Oil Cooler
Maintenance 10.16 Changing the cooling oil 5. Slowly open the shut off valve in the maintenance hose to release oil and close immediately when air escapes. 6. Close the shut-off valve and unplug the male hose fitting. Draining the oil from the cooler Fig.
Page 91: Fig. 34 Changing The Cooling Oil, Airend
Maintenance 10.16 Changing the cooling oil Draining the oil from the airend Fig. 34 Changing the cooling oil, airend Compressed air outlet on airend Safety screen Hose coupling (oil drainage) Coupling Shut-off valve 1. Have an oil receptacle ready. 2. With the shut-off valve closed, insert the male hose fitting (Fig.
Page 92: Fig. 35 Changing The Cooling Oil, Oil Tank
Maintenance 10.16 Changing the cooling oil Option K2 Draining the oil from the tank Fig. 35 Changing the cooling oil, oil tank Oil tank Male hose fitting Hose coupling (oil drainage) Shut-off valve Shut-off valve 1. Have an oil receptacle ready. 2.
Page 93: Changing The Oil Filter
Maintenance 10.17 Changing the Oil Filter Fig. 36 Changing the cooling oil, heat recovery system Hose coupling Thermostatic valve Shut-off valve 1. Have an oil receptacle ready. 2. Insert the male hose fitting (Fig. 32) in the hose coupling 3. Place the other end of the maintenance hose in the oil receptacle and secure it in place. 4.
Page 94: Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the Oil Separator Cartridge WARNING There is risk of burns from hot components and oil. ➤ Wear long-sleeved clothing and gloves. Fig. 37 Changing the oil filter Oil filter Direction to unscrew Changing the oil filter 1. Unscrew the oil filter counter-clockwise, catch oil spillage and dispose of in accordance with environmental protection regulations.
Page 95: Fig. 38 Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the Oil Separator Cartridge The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ adherence to the changing intervals for: ─ cooling oil ─ oil filter ─ air filter Material Replacement part...
Page 96 Maintenance 10.18 Changing the Oil Separator Cartridge 8. Attach the air pipe to the cover with a new, self-locking nut. 9. Replace and tighten all fittings. ➤ Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations. Start the machine and carry out a test run 1.
Page 97: Document Maintenance And Service Work
Maintenance 10.19 Document maintenance and service work. 10.19 Document maintenance and service work. Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 51 Logged maintenance tasks Service Manual Screw Compressor 9_5708 08 USE...
Page 98: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every inquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are selected for use in KAESER machines. WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuitable spares or operating fluids/materials.
Page 99: Service Addresses
11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Spare Parts for Service and Repair With the help of this parts list you can plan your material requirement according to operating conditions and order the spare parts you need.
Page 100 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_5708 08 USE...
Page 101 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_5708 08 USE...
Page 102 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_5708 08 USE...
Page 103 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_5708 08 USE...
Page 104: 12 Decommissioning, Storage And Transport
2. Disconnect all air and electrical connections. 12.2 Packing A wooden crate is required for ground transport to protect the machine from mechanical damage. Consult an authorized KAESER Service representative for advice on packing for sea or air transport. Material Desiccant Plastic sheeting...
Page 105: Transporting
Decommissioning, Storage and Transport 12.4 Transporting CAUTION Machine damage from moisture and frost. ➤ Prevent ingress of moisture and condensation. ➤ Maintain >32 °F storage temperature. ➤ Store the machine in a dry, frost-proof room. 12.4 Transporting 12.4.1 Safety Weight and center of gravity determine the suitable transporting method. The center of gravity is shown in the drawing in chapter 13.3.
Page 106: Disposal
Decommissioning, Storage and Transport 12.5 Disposal Fig. 40 Transporting with a crane Lifting cradle Slings CAUTION Machine damage by incorrect lifting cradle attachment. ➤ Do not attach the lifting cradle to any of the machine components. ➤ The machine manufacturer can advise on application of a suitable lifting cradle. ➤...
Page 107: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5708 08 USE...
Page 108 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5708 08 USE...
Page 109 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5708 08 USE...
Page 110 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5708 08 USE...
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Page 113: Pipe And Instrument Flow Diagram (P+I Diagram): Modulating Control Mode
Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode 13.2 Option C1 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor 9_5708 08 USE...
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Page 115 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor 9_5708 08 USE...
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Page 119: Dimensional Drawing
Annex 13.3 Dimensional Drawing 13.3 Dimensional Drawing Service Manual Screw Compressor 9_5708 08 USE...
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Page 123: Electrical Diagram
Annex 13.4 Electrical Diagram 13.4 Electrical Diagram Service Manual Screw Compressor 9_5708 08 USE...
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This manual is also suitable for:

Bsd 50 Bsd 60

KAESER BSD 40 Service Manual

1 Regarding this Document Using the Document

2 Technical Data Nameplate

3 Safety and Responsibility Basic Information

4 Design and Function

5 Installation and Operating Conditions

6 Installation Safety

7 Initial Start-Up Safety

8 Operation

9 Fault Recognition and Rectification

10 1 Maintenance

11 Spares, Operating Materials, Service

12 Decommissioning, Storage and Transport

13 Annex

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