Related Manuals for KAESER KOMPRESSOREN CSD 82
Summary of Contents for KAESER KOMPRESSOREN CSD 82
- Page 1 SERVICE MANUAL Screw Compressor Model: CSD No.: 9.5700.02E Manufacturer: KAESER KOMPRESSOREN GmbH 96410 Coburg PO Box 2143 GERMANY Tel. + 49 ---(0)9561 ---6400 Fax + 49 ---(0)9561 ---640130 http://www.kaeser.com...
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Page 3: Table Of Contents
Contents Chapter --- page Regarding this Document ........1 --- 1 Handling the Document . - Page 4 Contents Chapter --- page Design and Function ......... . 4 --- 15 Machine Overview .
- Page 5 Contents Chapter --- page Operation ........... 8 --- 32 Switching On and Off .
- Page 6 Contents Chapter --- page 11 Spares, Operating Materials, Service ......11 --- 68 11.1 Note the nameplate .
- Page 7 Directory of Illustrations Chapter --- page Fig. 1 Cabinet ............4 --- 15 Fig.
- Page 8 Table Directory Chapter --- page Tab. 1 Nameplate ............2 --- 3 Tab.
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Page 9: Regarding This Document
Regarding this Document Regarding this Document Handling the Document The service manual is part of the machine. Keep the service manual in a safe place throughout the life of the machine. Pass the manual on the next owner/user of the machine. Ensure that all amendments are entered in the manual. -
Page 10: Miscellaneous Notices And Symbols
Regarding this Document 1.4.2 Miscellaneous notices and symbols Here is a task to be carried out. This symbol identifies environmental protection measures. This indicates important information. 1 --- 2... -
Page 11: Technical Specification
Modulating control Transformer power supply for refrigeration dryer Tab. 2 Options Weight Maximum weights are shown. Actual weights of individual machines are dependent on equipment fitted. CSD 82 CSD 102 CSD 122 Weight [kg] 1300 1350 1400 Tab. 3 Machine weights... -
Page 12: Ambient Conditions
Technical Specification Ambient Conditions CSD 82 CSD 102 CSD 122 Maximum elevation [m] 1000 1000 1000 Ambient temperature [˚ C] 3 – 45 3 – 45 3 – 45 Inlet air / cooling air tempera- 3 – 45 3 – 45 3 –... -
Page 13: Fan Motor
Technical Specification CSD 82 CSD 102 CSD 122 Motor bearing greasing 2000 2000 2000 [operating hours] Grease requirement, each bearing [g]* * Transfer data from motor nameplate to the table Tab. 8 Compressor motor data 2.6.2 Fan Motor Air cooling (option K1) -
Page 14: Cooling Oil Volumes
— 54 ˚ C (DIN ISO 6614) Tab. 11 Recommended cooling oil 2.7.2 Cooling Oil Volumes CSD 82 CSD 102 CSD 122 Total charge [l] Top ---up volume [l] (minimum --- maximum Additional volume [l] (option W2) Additional volume [l] (option W3) Additional volume [l] (option W1) * * Input the additional volume corresponding to your heat recovery system. - Page 15 Technical Specification Rated power supply 230V 10%, 3 --- ph, 50Hz CSD 82 CSD 102 CSD 122 Pre---fuse [A] Supply [mm 4 x 95 4 x 120 Consumption [A] Tab. 13 Supply 230V/3/50Hz Rated power supply 400V 10%, 3 --- ph, 50Hz...
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Page 16: Water Cooling (Option K2)
Technical Specification Water cooling (option K2) 2.9.1 Design data Cooling water temperature rise 10 K CSD 82 CSD 102 CSD 122 Max. permissible discharge tempera- ture [˚ C] Max. permissible inlet temperature [˚ C] Cooling water volume [m Water pressure drop [bar] Tab. -
Page 17: Internal Heat Recovery (Option W2 / W3)
Technical Specification Hydrogen carbonate (HCO ) [mg/l] 70 ---300 Sulphate (SO ) [mg/l] < 70 / SO > 1 Electrical conductivity [ S/cm] 10 ---500 Ammonia (NH ) [mg/l] < 2 Dissolved magnesium (Mn) [mg/l] < 0,1 Dissolved aluminium (Al) [mg/l] <... - Page 18 Technical Specification Heat Exchanger Specification CSD 82 CSD 102 CSD 122 Maximum working pressure of the heat transfer medium [bar] Pressure drop [bar] < 0,1 < 0,1 < 0,1 Plate material 1.4401 1.4401 1.4401 Solder Maximum permissible temperature of the heat transfer medium [˚ C] Tab.
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Page 19: Safety And Responsibility
Safety and Responsibility Safety and Responsibility Disregarding this notice can result in serious injury! The machine is made to the latest technical safety standards and acknowledged safety regulations. Nevertheless, risk of injury and death for the user and third parties and dam- age to the machine and other property can arise from its use. -
Page 20: Safety Devices
Safety and Responsibility Operation in Germany: Recurring inspections in accordance with VBG 16 --- § 18 The company (user) must ensure that recurring inspections of safety devices on com- pressors with motor power greater than 0.5 kW are carried out by qualified persons. Inspection intervals of one year are generally sufficient. -
Page 21: Danger From Released Spring Force
Safety and Responsibility Work on the electrical equipment may only be carried out by a qualified electrician or by instructed persons under the supervision of a qualified electrician. Before the machine is switched on for the first time the user must provide and check measures to guard against electric shock by direct or indirect contact. -
Page 22: Warning Symbols
Safety and Responsibility Spare parts The use of unsuitable parts may adversely influence the safe working of the machine. Use only genuine KAESER spares for parts subject to pressure. Warning Symbols Beware of life---threatening electrical voltage. Do not touch electrical components; danger of electric shock. Before opening, switch off at the main switch and lock off to secure against unwanted or accidental switching on. -
Page 23: Design And Function
Design and Function Design and Function Machine Overview 4.1.1 Cabinet Fig. 1 Cabinet Control cabinet door Latch Removable panel The cabinet serves various purposes: sound damping protection cooling air flow control Safe and reliable operation can only be ensured with the cabinet closed. Latches are released by a key supplied with the machine. - Page 24 Design and Function Fig. 2 Air ---cooled machine Inlet valve [2] Control cabinet Coupling [5] Oil separator tank [6] Drive motor [3] Air filter [1] Oil filter [10] Oil/air cooler [11/13] Airend [4] Compressor Atmospheric air is cleaned as it is drawn in through the filter (8). The air is then compressed in the airend (5).
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Page 25: Options
Design and Function Options 4.2.1 Machine mountings (option H1) The machine mountings enable the machine to be anchored to the floor. 4.2.2 Cooling air filter mats (option K3) Mats filter the cooling air and keep the cooler surface clean. Fig. 3 Cooling air filter mats Cooling air filter mat 4.2.3... -
Page 26: Operating States And Control Modes
Design and Function Fig. 5 Internal heat recovery Plate heat exchanger [26] Operating States and Control Modes 4.3.1 Operating states There are three operating states: LOAD: the inlet valve is open. The airend delivers compressed air to the system. The drive motor runs under full load. IDLING: The inlet valve is closed. -
Page 27: Modulating Control (Option C1)
Design and Function When the maximum pressure is reached the machine switches to IDLING. When the preset idling time has elapsed the machine is switched to STANDSTILL. The shorter the idling time setting, the sooner and more frequently the motor is stopped. VARIO The VARIO control mode is an extension of DUAL control. -
Page 28: Sigma Control Keys And Indicators
Design and Function SIGMA CONTROL Keys and Indicators Fig. 6 SIGMA CONTROL keys Symbol Item Description Function ON (I) Switch the machine on. Programmed operating mode is active. OFF (0) Switch the machine off. Operating mode: Switching clock ---control on and off. Clock The LED lights when the machine is under clock control. - Page 29 Design and Function Symbol Item Description Function Events and infor- Displays the event memory. mation key Selection from every menu. Returns together with ’esc’ key (8). Acknowledge (re- Acknowledges (re---sets) messages and resets the set) key event memory (if permitted). Tab.
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Page 30: Installation And Operating Conditions
Installation and Operating Conditions Installation and Operating Conditions Ambient Conditions There must be no open flames or sparks at the place of installation. Any welding work carried out on the equipment must not cause a fire hazard through flying sparks or excessive temperature. The machine is not explosion ---proof. -
Page 31: Ventilation
Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually open. CSD 82 CSD 102 CSD 122 Inlet opening [m ] (option K1) ¡... -
Page 32: Operating In A Compressed Air Network
Installation and Operating Conditions CSD 82 CSD 102 CSD 122 Extractor for forced ventilating: 3000 3000 3000 Flow rate [m /h] at 100 Pa (option K2) Exhaust air duct: 700 x 700 700 x 700 700 x 700 Dimensions [mm] Tab. -
Page 33: Installation
Installation Installation Safety There is considerable danger of injury or death if insufficiently or inad- equately treated compressed air is used. DANGER Injury and/or poisoning caused by the use of insufficiently treated com- pressed air as breathing air or for the processing of foodstuffs. Never use compressed air as breathing air unless it has been suitably treated, the pressure is appropriately reduced and breathing appar- atus is used. -
Page 34: Electrical Connection
Installation Shut ---off valve (2) to be installed by the user in the connection line. Make the compressed air connection with a flexible hose (1) or an axial compensa- tor (1). Electrical Connection Have the electrical connection made only by a qualified and authorised electrician. Carry out protection measures as stipulated in relevant regulations (IEC 364 or DIN VDE 0100, for example) and in national accident prevention regulations (BGV A2 in Ger- many). -
Page 35: Heat Recovery System Connection
Installation Fig. 10 Water cooling connection Cooling water outlet 10 Shut ---off valve Cooling water inlet 12 Connection port with stopper 17 Pressure relief valve The user is to provide the following fittings: Dirt trap with max. 0.1 mm strainer mesh. Shut ---off valves (10) and connection ports (12) for maintenance and venting. - Page 36 Installation Fig. 11 Heat recovery Outlet 10 Shut ---off valve Inlet 12 Connection port with stopper 17 Pressure relief valve The user is to provide the following fittings: Dirt trap with max. 0.1 mm strainer mesh. Shut ---off valves (10) and connection ports (12) for maintenance and venting. Pressure relief valve (17) on the inlet (B) prevents build ---up of excessive pressure.
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Page 37: Initial Start
Initial Start--- up Initial Start---up Before Initial Start---up (or Recommissioning) A trained specialist may only carry out the initial start ---up procedure. Incorrect start ---up can cause damage to the machine. Special measures on recommissioning after storage Storage period longer Action than 12 months... -
Page 38: Motor Protection Switch Setting
Initial Start--- up Setting The standard setting is made at the factory. To prevent the overload protection cutout from being triggered by voltage fluctuations, tem- perature influences or component tolerances, the setting can be up to 15% higher than the arithmetical phase current. -
Page 39: Checking Direction Of Rotation
Initial Start--- up Remove the cover (3). Note the rotational direction arrow (4). Grasp the coupling (2) and turn it and the airend shaft (1). Replace the coupling cover (3). Checking Direction of Rotation The machine is designed for a clockwise field. Check the supply with a phase sequence indicator. -
Page 40: Operation
Operation Operation Fig. 14 Switching On and Off ’Machine ON’ LED (green) ’Remote’ key ’ON’ key (’I’) ’LOAD’ LED OFF key (’0’) ’IDLE’LED ’Clock’ key ’Power ON’ LED (green) LOAD / IDLE toggle key Switching On and Off Always switch the machine on and off with the ’ON’ and ’OFF’ keys. The supply disconnecting device is installed by the user. -
Page 41: Switching Off
Operation 8.1.3 Switching off Press the ’LOAD/IDLE’ toggle key (13). The machine switches to IDLE and the LED (7 blinks. After running in idle for 20 seconds, press the OFF key (3). The ’Machine ON’ LED goes out (1). Switch off and lock out the main supply isolator. Switching Off in an Emergency and Switching On Again Fig. -
Page 42: Switching On And Off With The Clock
Operation Apply the remote warning label to the machine where it is plainly visible. BEWARE! This machine is remotely controlled and can start at any time. Label the remote control device accordingly: ”Before starting, make sure that no one is working on the machine and it can be safely started.”... -
Page 43: Resetting Warning Messages
Operation Press the ’Acknowledgement (reset)’ key (12). The alarm LED (red) goes out (11). The machine is now ready to start again. 8.5.2 Resetting warning messages Pre --- condition: The cause of the warning eliminated. Maintenance task completed. Press the ’Acknowledgement (reset)’ key (12). The warning LED (yellow) goes out (10). -
Page 44: Event Recognition And Fault Rectification
Event Recognition and Fault Rectification Event Recognition and Fault Rectification Inform KAESER service if the event cannot be rectified by the action suggested. Do not attempt rectifications other than those given in this manual. The measures valid for your machine are dependant on the individual equipment. There are three types of event: Description Indicated by... - Page 45 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only AI 3 open cct. No connection be- Check line and con- Check the sensor. tween the sensor nection. measuring airend di- scharge tempera- ture and the analog input 3.
- Page 46 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only EMERGENCYSTOP EMERGENCY STOP Unlatch the push- button pressed. button. ext. message 0 Rectify fault. ext. message 5 Fan M2 I First fan motor shut Investigate cause. down because of Reset overload trip.
- Page 47 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only no press. buildup Machine produces Check for air leaks. Check the inlet no compressed air. valve. Check the coupling / The setpoint pres- V---belts. Check minimum sure does not rise pressure/check above 3.5 bar for a valve.
- Page 48 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only RD compr. T Refrigerant comp- Clean the refrigerant ressor overheating. condenser. Ensure adequate ventilation. Install an extractor. Cleaning the cooler RD compr. T Refrigerant comp- Check refrigeration ¡...
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Page 49: Warning Messages (Yellow Led Blinking)
Event Recognition and Fault Rectification Warning Messages (yellow LED blinking) Message Possible cause Action KAESER service technician only access doors Doors opened dur- Close access doors. ing machine opera- tion. The maximum per- Ensure adequate missible airend di- ventilation. scharge tempera- Clean the cooler. - Page 50 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only error: RS 485 Wrong configuration Check the link/inter- or transmission er- face connections ror. between the two controllers. Bit rate and charac- ter frame for both Check maximum subscribers identi- cable length and cal.
- Page 51 Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only no press. buildup The compressor Check for air leaks. Check the minimum cannot build ---up pressure/check Check the value gi- pressure. valve, the control ven in the analog valve and the inlet data menu with the valve.
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Page 52: Miscellaneous Events (Faults)
Event Recognition and Fault Rectification Message Possible cause Action KAESER service technician only separator h The service interval Change the oil sepa- to the next oil sepa- rator cartridge. rator cartridge check has expired. set output The ’set output’ test End the ”set output”... - Page 53 Event Recognition and Fault Rectification Alarm Possible cause Action KAESER service technician only Machine runs but Inlet valve not ope- Check the valve. produces no comp- ning or only opening ressed air. ressed air. partially. Venting valve not Check venting valve. closing.
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Page 54: Maintenance
Maintenance Maintenance 10.1 Safety Disregarding these notes and/or improper handling may result in serious injury. Electric shock can kill! DANGER Touching electrically live components can cause serious injury or death. Isolate completely from the mains supply (all conductors) (switch off at the main isolator) Ensure the supply cannot be switched on again (lock off). -
Page 55: Maintenance Schedule
Maintenance Maintenance work may only be carried out: by persons trained in the machine and persons under the supervi- sion of an expert, by experts, by an authorised KAESER service agent. Work on electrical devices may only be carried out in accordance with elec- trical regulations: by persons trained in the machine under the supervision of an electrician,... -
Page 56: Regular Maintenance Work
Maintenance 10.2.2 Regular maintenance work When operating conditions are unfavourable (e.g. dusty atmosphere) or when the equipment is heavily utilised, maintenance tasks must be carried out more frequently (shorter intervals). Heed controller maintenance messages. Have KAESER service adjust the maintenance interval counters to suit operating conditions. -
Page 57: Regular Service Work
Maintenance 10.2.4 Regular service work Only authorised KAESER service agents should carry out service work. When operating conditions are unfavourable (e.g. dusty atmosphere) or when the equipment is heavily utilised, service work must be carried out more frequently (shorter intervals). Interval Maintenance tasks Up to 12000 h... -
Page 58: Cooler Maintenance
Maintenance 10.3 Cooler Maintenance 10.3.1 Air cooling (option K1) Material: brush vacuum cleaner Pre --- condition: Machine switched off. Mains isolator locked off Machine cooled down. Check the cooler regularly for contamination. Frequency is mainly dependant on local op- erating conditions. Contamination causes overheating and machine damage. -
Page 59: Water Cooling Maintenance (Option K2)
Maintenance Fig. 18 Cooler filter mats Filter mat Retaining frame Fixing Removal Unlock the fixings (3). Use a screwdriver to turn the fixing 90˚ anti---clockwise. Remove the frame (2). Cleaning Beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat in lukewarm water and household detergent then rinse thoroughly. -
Page 60: Internal Heat Recovery Maintenance (Option W2 / W3)
Maintenance 10.4 Internal Heat Recovery Maintenance (option W2 / W3) Pre --- condition: Machine switched off. Mains isolator locked off Machine cooled down. Deposits in the heat exchanger in machines with heat recovery systems can adversely af- fect heat transfer. Check the heat exchanger regularly for leaks and contamination. -
Page 61: Filter Mat Maintenance (Control Cabinet Ventilator)
Maintenance Open the air filter housing: Pull the retaining clips (1) outwards and remove the cap (2). Pull out the air filter cartridge (3) by turning lightly. Clean the sealing surfaces and the air filter housing. Do not wet ---clean the air filter element. Clean the air filter cartridge by tapping Renew the cartridge after two years or after it has been cleaned five times. -
Page 62: Electric Motor Maintenance
Maintenance Removal Remove the ventilator grill (1) and the filter mat (2). Cleaning Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat in lukewarm water and household detergent then rinse thoroughly. Renew the mat if cleaning is not possible of has already been carried out five times. Replacing Lay the filter mat in the frame and push on the grill to latch. -
Page 63: Checking The Coupling
Maintenance 10.8 Checking the Coupling Danger of injury from rotating coupling! WARNING Severe injury could result from touching the coupling while it is rotating. Never switch the machine on without the guard in place over the coupling. The coupling must be carefully inspected at regular intervals. A defective coupling is recognisable by: ¡... -
Page 64: Venting The Machine Manually
Maintenance 10.9 Venting the Machine Manually Pre --- condition: Machine switched off. Mains isolator locked off Machine cooled down. Compressed air can cause injury or death. WARNING Compressed air and devices under pressure can injure or cause death if the contained energy of the air is released suddenly or uncontrolled. After shutting down the compressor and venting the oil separator tank there is still pressure on the check valve from the air main. -
Page 65: 10.10 Checking And Topping Up The Cooling Oil
Maintenance Fig. 23 Ventilate the machine. Hose coupling (air cooler venting) Male hose coupling/fitting Pressure gauge Shut ---off valve A: closed B: open Hose coupling (oil separator tank ven- Maintenance hose ting) Check that the oil separator tank pressure gauge reads zero. After automatic venting the pressure gauge does not read zero? Make sure that the shut ---off valve is closed. -
Page 66: 10.10.2 Topping Up The Cooling Oil
Maintenance Fig. 24 Check cooling oil level. Oil separator tank Minimum oil level Oil level indicator Oil level optimum Indicator markings Oil level maximum Green zone Readout oil level. When the indicator shows minimum level, top up the oil. 10.10.2 Topping up the cooling oil Material: Cooling oil Pre --- condition: Machine switched off... - Page 67 Maintenance Fig. 25 Topping up the cooling oil Hose coupling (air cooler venting) Oil level indicator Pressure gauge Male hose coupling/fitting Hose coupling (oil separator tank ven- Shut ---off valve ting) A: closed B: open Oil filling port with plug Maintenance hose Check that the oil separator tank pressure gauge (2) reads zero.
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Page 68: 10.11 Changing The Cooling Oil
Maintenance 10.11 Changing the Cooling Oil Material: Cooling oil Have the oil container ready. Thoroughly drain the oil from the separator tank, the cooler and the heat recovery system if fitted. Dispose of the old oil in accordance with local environment protection regulations. - Page 69 Maintenance Close the shut ---off valve (10) in the venting line. Start the machine in idle and watch the oil separator tank pressure gauge (2) until it reads 3 ---5 bar. Switch the machine off. Switch off and lock out the main supply isolator. Wait at least two minutes for oil to flow back to the separator tank.
- Page 70 Maintenance Draining the oil from the cooler Fig. 27 Changing the Cooling Oil Oil cooler Male hose coupling/fitting Hose coupling (oil drain) Shut ---off valve Shut ---off valve Have the oil container ready. With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl- ing (2).
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Page 71: 10.12 Oil Filter Maintenance
Maintenance Switch on the power supply and reset the maintenance interval counter. Allow the machine to idle for at least one minute. Then switch to LOAD. After about five minutes, check the oil level and top up if necessary. Carry out a visual check for leaks. 10.12 Oil filter maintenance Material: Spare parts... -
Page 72: 10.13 Checking The Pressure Relief Valve
Maintenance Start the machine and carry out a test run Close all access doors; replace and secure all removable panels. Open the user’s shut ---off valve between the machine and the air main. Switch on the power supply and reset the maintenance interval counter. Allow the machine to idle for at least one minute. -
Page 73: 10.14 Changing The Oil Separator Cartridge
Maintenance 10.14 Changing the Oil Separator Cartridge Material: Spare parts Precision pressure gauge Cleaning rags Pre --- condition: Machine switched off. Mains isolator locked off Machine fully vented (no pressure). Pressure gauge on the oil separator tank indicates zero. Machine cooled down. The life of the oil separator cartridge is influenced by: contamination in the air drawn into the compressor, adherence to the schedule of oil and air filter changes,... - Page 74 Maintenance Dispose of parts and materials contaminated with oil in accordance with local environment protection regulations. Take out the old oil separator element (23) together with the gaskets (21) and dispose of according to environmental regulations. Wipe all sealing faces with a cleaning rag. Insert the new oil separator cartridge with gaskets and re---fix the cover.
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Page 75: 10.15 Logging Maintenance Work
Maintenance 10.15 Logging Maintenance Work Machine number: Date Maintenance task carried out Operating hours Signature Tab. 38 Maintenance log 10 --- 67... -
Page 76: Spares, Operating Materials, Service
Spares, Operating Materiels, Service Spares, Operating Materials, Service 11.1 Note the nameplate Take data from the nameplate for all enquiries and spare parts orders. 11.2 Ordering Maintenance Parts and Operating Materials Personal injury or machine damage may result from the use of unsuit- able spare parts or operating materials. -
Page 83: Packing
De --- commissioning, Storage and Transport De---commissioning, Storage and Transport 12.1 De ---commissioning De---commissioning is necessary when: the machine will not be needed for some time, the machine is to be moved to another location, the machine is no longer needed, the machine is to be scrapped. -
Page 84: Transporting
De --- commissioning, Storage and Transport 12.4 Transporting Use only a fork truck or lifting cradle. Take weight and centre of gravity into consideration. The centre of gravity is shown in the drawing in chapter 13.2.3. The water cooling system of water ---cooled machines must be drained completely if there is danger of frost. -
Page 85: Annex
Annex Annex 13.1 Conformity Machines with CE mark conform to European directives and may be operated in the EU. A Declaration of Conformity is provided with the machine. 13.2 Diagrams and Drawings 13.2.1 Pipeline and instrument flow diagram (P&I diagrams) 13 --- 77... -
Page 91: Pipeline And Instrument Flow Diagram (Option C1)
Appendix 13.2.2 Pipeline and instrument flow diagram (option C1) 13 --- 83... -
Page 97: Dimensional Drawing
Appendix 13.2.3 Dimensional drawing 13.2.3.1 Air cooling (option K1) 13 --- 89... - Page 100 Appendix 13.2.3.2 Water cooling (option K2) 13 --- 92...
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Page 103: Electrical Diagram
Appendix 13.2.4 Electrical diagram 13 --- 95...
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