KAESER SK 19 Service Manual

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SERVICE MANUAL

Screw Compressor

Model: SK 19

GL---Nr.: BA---SK19.L---1.9760.50011---00 03

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Wye---Delta Start

D.O.L. Start

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Wiring Diagram:

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Serial No.:

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USE

Volt

Cabinet heaters

115 V receptacle

Outdoor modification

psig

Rainhoods

Switchable Modulation

Synthetic lubricant

Food Grade lubricant . . . . . . . . . . . . . . . . .

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Summary of Contents for KAESER SK 19

Page 1 SERVICE MANUAL Screw Compressor Model: SK 19 GL---Nr.: BA---SK19.L---1.9760.50011---00 03 ......Volt Cabinet heaters Wye---Delta Start 115 V receptacle D.O.L.
Page 2: Table Of Contents
1 --- 3 1.8.3 Compatibility of KAESER Sigma Lubricants ......1 --- 4 Maintenance for the Electrical Motor .
Page 3 Table of Contents Chapter --- Page Putting into Operation ......... . 7 --- 22 Points to be Observed before Putting into Operation .
Page 4 Table of Contents Chapter --- Page 9.13.1 Removing and cleaning the oil cooler/air aftercooler ..... . 9 --- 49 9.14 Oil Change (Oil Separator Tank and Oil Cooler) .
Page 5: Technical Specification
......... . . SK 19 Maximum gauge working pressure .
Page 6: Set Point Of The Safety Relief Valve
Installation Requirements Max. height above sea level of the place of installation 3000 ft. (for all heights above please contact authorized KAESER distributor) 40 EF Min. ambient temperature ......
Page 7: Fluid Recommendations
KAESER synthetic lubricants should be stored in a protected location to prevent conta- mination. Do not re---use drums; flush and send to reconditioner. Although the KAESER synthetic is not highly flammable, it will burn. While KAESER syn- thetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classi- fied as a fire---resistant fluid.
Page 8: Compatibility Of Kaeser Sigma Lubricants
1.8.3 Compatibility of KAESER Sigma Lubricants All the above listed KAESER Sigma lubricants are similar to mineral oil in their compatibility with paints, seals, gaskets and hoses. The typical precautions are required when changing over from mineral oil to KAESER synthetic hydrocarbon based lubricant.
Page 9: Maintenance For The Electrical Motor
Technical Specification ACCEPTABLE NOT RECOMMENDED Viton Celcon High Nitrile Buna N Neoprene Teflon SBR Rubber Epoxy Paint Low Nitrile Buna N Oil Resistant Alkyd Acrylic Paint Nylon Lacquer Delrin Polystyrene Attention! Polycarbonate bowls can be etched by any synthetic lubricant. We recommend replacement with metal bowls, or the addition of metal guards.
Page 10 Technical Specification 1 --- 6...
Page 11: Safety Regulations
Safety Safety Regulations Read this service manual carefully and observe cautionary references before putting this compressor package into operation and before carrying out any maintenance. Explanation of Symbols and References This symbol is placed before all references to safety where danger to life and limb can occur during work.
Page 12: General Safety Precautions
Unless the Service Manual states otherwise, all pressure lines must be vented or shut off. Attention! Any alterations or reconstruction carried out without the prior written authorization of KAESER COMPRESSORS Inc. will invalidate the war- ranty. Attention! No welding, heat-- treatment or mechanical modifications may be car- ried out on pressurised components such as.
Page 13: Electrical Power Supply
These recommendations do not supersede other applicable codes. Spare Parts Safe and reliable operation of the compressor package is guaranteed only with KAESER original spare parts and KAESER SIGMA cooling oil. Use only original parts in assemblies subject to pressure.
Page 14: Environmental Protection
Safety Environmental Protection Condensate drainage The condensate accumulating during compression must be fed via a suitable drainage system, collected in special canisters and disposed of according to environmental regulations. Maintenance materials/wear items/replacement parts Ensure that all wear items, maintenance and replacement parts accu- mulating during operation of the compressor package are disposed of according to environmental regulations.
Page 16: Transport
The machine should be protected from mechanical damage by a sturdy crate and from moisture by plastic sheeting. By sea or air Special packaging instructions can be obtained from KAESER. Dispose of the packaging according to environmental regulations and recycle where possible.
Page 17: Storage
Storage If the equipment is to stand idle for a long period the prescribed measures must be taken to avoid damage. If any measures can not be taken, advice should be sought from an authorized KAESER distribitor. Attention! Basically, the equipment should be stored in a dry, frost-- free room.
Page 18: Construction And Operation
Construction and Operation Construction and Operation Principle of Compression The stationary compressor package is fitted with a single stage, oil---injected airend. The two rotors, the driven male rotor and the female rotor, both mounted in antifriction bear- ings, are fitted into the airend. As the rotors rotate, air is drawn into the upper side through the inlet port and is compressed on the lower side.
Page 19 Construction and Operation 5 --- 15...
Page 20 Construction and Operation 5 --- 16...
Page 21: Dual Control
Construction and Operation DUAL Control Full load Idle Standstill Time In DUAL Control (combined idle and start ---stop) the compressor normally runs at full -- load, idle or standstill. The controller regulates the compressor package between full -- load and idle. If the compressor package runs in idle for longer than the preset period (1) to (2), for example t = 6 min, the drive motor is stopped completely (2).
Page 22: Quadro Control
Construction and Operation QUADRO Control p min Full load Idle Standstill Time rise decay Running period Idle/ standstill period Run ---on period Stop point for the running period or idle / standstill period upper switching point lower switching point pressure rise time (the time during which the air system pressure rises rise from the lower to the upper switching point) pressure decay time (the time during which the air system pressure decays...
Page 23: Vario Control
Construction and Operation If the air systems pressure rises to the upper switching point and the running period has already expired, the compressor package is switched off after the run ---on period has expired (2). If the air systems pressure rises to the upper switching point before the running period has expired then the pressure decay time of the previous switching cycle is taken as the criterium for the selection of the operating mode: -- If the pressure decay time t...
Page 24: Installation
Installation Installation Installation Requirements Attention! The compressor should be mounted on level surface. For any special application please consult with the manufacturer. Safe operation of the compressor package is only ensured if the ambient temperature re- mains within the limits stated in chapter 1.6). If the compressor is used in the open, take care that it is protected against the direct rays of the sun and against the ingress of dust and rain.
Page 25: Connection Of The Compressed Air Supply
Installation Solution B: Exhaust Air used for Space Heating The hot air is forced through a conduit (see chapter 1.6) into the room to be heated. Attention! Consult the manufacturer with regard to length of conduit and for maximum allowable pressure drop for this compressor package. Safe operation of the compressor package is guaranteed only if the temperature limits (see chapter 1.6) of the cooling air are adhered to.
Page 26: Putting Into Operation
Initial Start Putting into Operation Points to be Observed before Putting into Operation Every compressor package is given a test run at the factory and carefully inspected before shipment. The test run confirms that the package conforms to the specification data and runs perfectly.
Page 27 Initial Start During installation of the compressor unit, ensure that a distance of at least 40 ” is kept between the cooling air intake of the unit and any wall. Check the oil level in the oil separator tank (see chapter 9.12). Check that the airend rotates in the correct direction (see chapter 7.4).
Page 28: Checklist
Initial Start Checklist Is the floor at the place of installation solid and level? yes no Is the space large enough for the compressor package or its components? yes no Are inlet and exhaust air apertures available in sufficient size and number? yes no Are all components of the compressor package easily accessible? yes no...
Page 29: Direction Of Rotation Check
Initial Start Direction of Rotation Check Attention! The compressor is wired for connection to a clockwise phase se- quence power supply. A check of the direction of rotation can be made by testing the phase sequence. Arrows showing the direction of rotation are located on the motor and on the airend hous- ing.
Page 30: Motor Overload Relay Adjustment And Changing
Initial Start Motor Overload Relay Adjustment and Changing Lock the main disconnect in the “off” position in accordance with ap- plicable lock out/tag out procedures (example: OSHA CFR 29 § 910.147) to ensure that the compressor does not restart. See chap- ter 2.3 for the main disconnect switch.
Page 31: Setting The Air System Pressure
Initial Start 1 Motor overload (rated power supply) 2 Motor overload (alternative power supply) 3 Reset button 4 Motor overload adjustment Setting the Air System Pressure The air system pressure is preset at the factory. It can be changed in SIGMA CONTROL to match customer’s operational requirements if the password is known.
Page 32: Functional Check Of The Door Interlock Switch
Initial Start Functional Check of the Door Interlock Switch Do not operate the compressor unit with a malfunctioning door inter- lock switch. Do not attempt to modify or by-- pass the door interlock switch. 1 Door interlock switch Visual door interlock switch check Check that the interlock switch operates smoothly by opening and closing the left --- hand maintenance door.
Page 33 Initial Start 1 Door interlock switch Bolt 2 Clamping nut Frame 3 Insertion key Maintenance door Functional check of the interlock switch A functional check of the door interlock switch must be made after in- Attention! itial start. Start the compressor package (see chapter 8.3). Open the left ---hand maintenance door --- the compressor package will shut down im- mediately if the door interlock switch functions correctly.
Page 34: Measures To Be Taken Before Initial Start
Initial Start Measures to be taken before Initial Start Follow the procedure detailed bellow before initial start, after an oil change or if the com- pressor has not been operated for a period of three months or longer before starting the compressor: 7.8.1 Pour a small quantity of oil into the air inlet port...
Page 35: Operation
Operation Operation Control Panel 1 SIGMA CONTROL 2 EMERGENCY STOP pushbutton SIGMA controller The SIGMA controller (1) is fitted in the control cabinet in the compressor package and serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor pack- age is determined by the settings programmed into the controller.
Page 36: Function Keys
Operation 8.2.2 Function keys 1 ON key (“I”) Menu scroll --- DOWN key 2 OFF key (“0”) Menu scroll --- UP key 3 Timer ON/OFF key Escape key 4 Remote ON key Return key 5 Load/idle key Info --- event key Acknowledge (reset) key 8.2.3 Light emitting diodes and plain text display...
Page 37: Starting And Stopping The Compressor Unit
Operation Starting and Stopping the Compressor Unit Attention! Do not start and stop the compressor package with the main discon- nect switch. The compressor must always be switched ON and OFF with keys (1) and (2). To turn the compressor ON (local): Switch on the main disconnect switch.
Page 38: Acknowledgement Of Service Messages
Operation Acknowledgement of Service Messages When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes. Maintenance due is shown in the display (12). A list of service messages that may occur during operation is included in the SIGMA CONTROL service manual. Carry out the maintenance work.
Page 39: Faults: Possible Cause
Operation Faults: Possible cause --- Remedy The removal of faults that are not explicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agency. 8.6.1 Working temperature too high Possible cause:...
Page 40: Compressor Runs But Does Not Reach Pressure
Arrange a supply of cooler air or move the machine to a cooler place (see chapter 1.6) Motor defective; bearing damage or Have the motor repaired or replaced winding short by an authorized KAESER Service Centre. 8.6.3 Compressor runs but does not reach pressure. Possible cause: Remedy: Motor turning in the wrong direction.
Page 41: Full
Full -- load/Idle sequence occurs too frequently (short cycles) Possible cause: Remedy: Receiver tank size is too small or there Consult authorized KAESER distributor is no tank. for recommended tank size. Diameter of hose connecting the unit Connecting hose diameter should not to the receiver tank is too small.
Page 42 Operation Possible cause: Remedy: Oil separator cartridge mountings are Tighten mounting bolts. loose. Oil level in separator tank is too high. Drain oil to correct level. Scavenger line is clogged. Inspect dirt trap strainer in scavenger line. Clean or replace clogged parts as necessary.
Page 43: Maintenance
Maintenance Maintenance Observe the following rules during all maintenance and servicing work: Work on power driven equipment may only be carried out by trained or specialized personnel. Follow all applicable OSHA and local safety regulations. If a power failure occurs, the compressor package starts again auto- matically (normal setting) provided the line pressure is lower than the pressure threshold parameter entered in SIGMA CONTROL.
Page 44: Regular Maintenance
6000/12000 hours or at Have the compressor motor bearings relubrica- least within three years ted by authorized KAESER distributors* * The maintenance period can vary depending on the cycle rate and environmental conditions. We urgently recommend that a record is kept of the maintenance work done (see chap- ter 9.16).
Page 45: Opening And Closing The Compressor Package
Maintenance Opening and Closing the Compressor Package To open: Open the maintenance door (1). Move the lever (A) in the direction of the arrow and lift up the maintenance door (2). Loosen the screws (B) and remove the panel (3). To close: Close the panel (3) the maintenance door (2) and the maintenance door (1) in the re- verse order.
Page 46: Checking The Drive Belt Tension
Remove the V---belts. Attention! It is essential that replacement belts are all precisely the same length (each set) and absolutely oil -- proof. For this reason we recommend that only original KAESER drive belts are used. 9 --- 42...
Page 47: Cleaning Or Replacing The Filter Mat
Maintenance Place the new V---belts over the motor and compressor pulleys without straining them. Set the belt drive tension (see chapter 9.4). Attention! Check the belt drive tension after 2 hours of operation and then again after 24 hours of operation, as experience shows that the belts stretch mostly during this period.
Page 48: Cleaning Or Replacing The Air Filter
Screw on the wing nut (3) tightly. Servicing the Electric Motor Compressor motor: The electrical motor bearings are permanently greased. Have the motor bearings replaced by authorized KAESER distributors Attention! in accordance with the maintenance schedule (see chapter 1.9). 9 --- 44...
Page 49: Testing The Safety Relief Valve On The Oil Separator Tank
SIGMA CONTROL. See chapter 1.5 for the safety relief valve activating pressure. Attention! Have the safety relief valve tested by an authorized KAESER distribu- tor in accordance with the maintenance schedule (see chapter 9.2). For more details see SIGMA CONTROL manual.
Page 50: Oil Filter Change
Maintenance The pressure gauge on the oil separator tank must indicate zero psig. Oil mist can escape when the oil separator tank is vented. Insert the nozzle (6) in the hose coupling (3) on the oil separator tank. The residual pressure in the oil separator tank escapes.
Page 51: Oil Top
Maintenance 1 Oil filter cartridge 2 Turn in this direction to unscrew the cartridge Twist the used or contaminated oil filter cartridge counter clockwise to remove and catch escaping oil in a suitable container. Dispose of the old oil filter and any used, accumulated oil according to environmental care regulations! Clean the face of the combination block with a lint free cloth.
Page 52 Maintenance Venting the compressor package (see chapter 9.10). 1 Ball valve 4 Filler plug 8 Maximum oil level A shut (oil top --- up) 9 Ball valve --- oil drain B open 5 Oil separator tank 10 Oil drain hose 2 Pressure gauge 6 Nozzle 11 External pressurization...
Page 53: Cleaning The Oil Cooler And Aftercooler
Maintenance 9.13 Cleaning the Oil Cooler and Aftercooler The oil cooler and air aftercooler must be checked for clogging regularly. Heavy contami- nation could lead to excessive temperatures in the oil circulation system. See regular maintenance schedule for cooler maintenance interval (chapter 9.2). Switch off the compressor package under full load (see chapter 8.3).
Page 54 Maintenance 5 Hexagonal nut 6 Allen screw Unscrew the hex bolt (5). The hex socket head bolts (6) are located behind two protective caps. Attention! Before unscrewing the two hex socket head bolts (6) prop up the com- bination oil/air aftercooler. Remove the protective caps and unscrew the two hex socket head bolts (6).
Page 55: Oil Change (Oil Separator Tank And Oil Cooler)
Maintenance 9.14 Oil Change (Oil Separator Tank and Oil Cooler) For type of oil and frequency of oil change see chapter 1.8 Oil change must be carried out with warm to the touch condition of the compressor pack- age (Oil temperature approx. 104•F). Danger of scalding with hot oil.
Page 56: Oil Change Using External Pressure Source
Maintenance 1 Ball valve 4 Filler plug 8 Maximum oil level A shut (oil top --- up) 9 Ball valve --- oil drain B open 5 Oil separator tank 10 Oil drain hose 2 Pressure gauge 6 Nozzle 11 External pressurization 3 Hose coupling 7 Minimum oil level Before opening or removing pressurized components (pipes, hoses,...
Page 57: Oil Top
Maintenance Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized. Venting the compressor package (see chapter 9.10). 1 Oil drain plug (oil cooler) Drain the oil from the oil cooler: Prepare an oil container to catch the escaping oil.
Page 58: Draining The Oil Using Own Compressed Air
Maintenance 9.14.3 Draining the oil using own compressed air Shut down the compressor unit under full load (see chapter 8.3). Lock the main disconnect in the ”off” position in accordance with ap- plicable lock out/tag out procedures to ensure the compressor does not restart.
Page 59: Changing The Oil Separator Cartridge
Maintenance Perform a test run When the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.3) and lock the main disconnect in the ”off” position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the compressor does not restart.
Page 60 Maintenance Do not remove the staples (7) in the gaskets (6). The metal parts of the oil separator cartridge are electrically conduc- tive and thus have to be grounded: The gaskets (6) are supplied with heavy staples to provide an electri- cal path from the oil separator tank to the frame of the compressor unit.
Page 61: Maintenance Schedule
Maintenance 9.16 Maintenance Schedule Model No....... . Serial No......Date Description of work Operating hours...
Page 62: Spare Parts And After Sales Service
Spare Parts and After Sales Service 10.1 Service parts and maintenance parts The removal of faults that are not explicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agent. (see chapter 9.1). Model Part No.
Page 63: Service And Maintenance Agreement
Dirt screen filter Gasket V---belt set 1800 10.2 Service and Maintenance Agreement We recommend that you take out a service and maintenance agreement with an author- ized KAESER distributor. This is your best guarantee of reliable air supplies. 10 --- 59...
Page 64: Appendix
Appendix Appendix 11.1 Wiring Diagram 11 --- 60...
Page 81: Spare Parts List
Appendix 11.2 Spare Parts List 11 --- 77...

KAESER SK 19 Service Manual

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