Related Manuals for Kaishan KRSD Series
Summary of Contents for Kaishan KRSD Series
- Page 1 KRSD Series Rotary Screw Air Compressor Instruction Manual (Controller MAM-6090) PN: 96002015000010 Release 2016, Version: A...
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Page 2: Table Of Contents
Fluid Change and Recommendations……………………………………..……13 4. Installation……………………………………………………………………………..14 Compressor Mounting, Support and Location…………………………………14 Ventilation and Cooling……………………………………….…………………14 Piping Connection………………………………………………………....15 Fluid Level Inspection………………………………………….…………………16 Electrical………………………………………..…………………………………17 Motor Rotation Inspection…………………………………………...…………...17 Fan Rotation Inspection …………………………………………….……………18 5. Operation…………………………………………………………………….………...19 Routine Operation…………………………………………….…………………..19 Electronic controller basic operation…………………………………………20 Program structure…………………..…………………………… ………………23 KRSD series Page 2... - Page 3 Technical parameters….…………………………………………………………41 Alarms………..…………………………………………………………………43 6. Servicing………………………………………………………………………………..44 Fluid Change……………………………………………………………..……..44 Air Filter……………………………………………………………………….…..44 Fluid Filter………………………………………………………………………..45 Air/Oil Separator………………………………………………………………….45 Fluid sampling procedure……………………………………………………….45 Maintenance Schedule…………………………………………………………….46 7. Troubleshooting Guide.………………………………………………………………48 8. Standard Terms and Conditions ……………………………………………….…..51 Page 3 KRSD series...
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Page 4: Safety Information
This manual must be kept in the safe place for future reference. Kaishan Compressor’s authorized distributors provide maintenance service for KRSD series rotary screw compressors. A certified technician is required to ensure compressors maintenance is safely handled. By following the instructions in this manual, the user will minimize possibility of an accident throughout the useful life of this equipment. -
Page 5: Safety Precautions
This manual describes the safety precautions, structure, and functions of all systems and components, as well as the operation and maintenance methods for the KRSD series rotary screw air compressors. The owner and operator shall read the manual carefully. Only after thorough understanding should the machine be operated for the first time. -
Page 6: Moving Parts
Keep personnel away from the compressed air discharge. Use compressed air for cleaning purpose only with effective chip guarding and personal protective equipment which meet OSHA standard and/or any federal, state, local codes, standard and regulation. KRSD series Page 6 1.8 ELECTRICAL SHOCK... - Page 7 Every effort has been taken to ensure complete and correct instructions have been included in this manual. However, possible product updates and changes may have occurred since printing this manual. Kaishan Compressor USA reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold.
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Page 8: General Information
General Information 2.1 INTRODUCTION The KRSD series offer models with power ranging from 30 hp to 50 hp. These direct driven compressors have standard full load pressure rating from 100 psi to 175 psi (7 bar to 13 bar). The compressor is a single stage, positive displacement, fluid-flooded rotary screw. -
Page 9: The Compression Cycle
After air/fluid mixture is discharged from compressor to the reservoir, fluid is separated from the air in the separator tank. Compressed air then flows through the after-cooler for moisture removal while the lubricant is being cooled by the fluid-cooler for re-injection. Page 9 KRSD series... -
Page 10: Compressor Lubrication And Cooling System
The minimum pressure check valve assures the reservoir maintains a minimum pressure between 58 psig and 72 psig (4Bar and 5Bar) during unloading conditions. This pressure is necessary for air/fluid separation and fluid circulation. KRSD series Page 10... -
Page 11: Airend, Inletvalve And Filtration System
It is also acts as the check valve to prevent the reverse pressure and rotation when compressor is shutting down. Air end Inlet valve Casing for air filter Page 11 KRSD series... -
Page 12: Fluid Information
Fluid Information 3.1 FLUID GUIDE KRSD compressors are filled & tested with Kaishan lubricant. Refer Figure 3-1 for filler port, sight glass, quarter-turn valve location on the reservoir. The compressor is filled with the manufacturer’s recommended quantity of Kaishan fluid. Inspection of the reservoir fluid level during installation or operation is recommended. -
Page 13: Fluid Change And Recommendations
Every 8,000 hours Every 4,000 hours Every 2,000 hours (4,000 hours for KTL4000 FG or as indicated by or as indicated by “spin on” type sampling report Delta P separator) or as indicated by Delta P Page 13 KRSD series... -
Page 14: Installation
Do not remove any warning, caution or instructional material attached with unit. 4.2 VENTILATION AND COOLING Ambient temperature should not exceed 40°C (104°F). High ambient temperatures may result in high air temperature shutdown. KRSD series Page 14... -
Page 15: Piping Connection
Never use PVC pipe or non-genuine rubber hose in the air system. Use flexible connections to prevent pipe load from being transmitted to the compressor. Never use a different pipe size other than the manufacturer specification for the compressor unit. Page 15 KRSD series... -
Page 16: Fluid Level Inspection
Inspect the fluid level when the compressor is in shut down mode. Fluid level is indicated on the reservoir sight glass. The maximum fluid level is at the top red-mark. Add fluid until KRSD series Page 16 the top red-mark is reached. -
Page 17: Electrical
Air compressors must be grounded in accordance with applicable codes, regulations and requirement. Kaishan Compressor would like to emphasize the importance of providing adequate grounding for air compressors. The common practice of grounding units to a building’s structural steel may not provide adequate grounding... -
Page 18: Fan Rotation Inspection
A centrifugal fan can pull the airflow across the coolers when rotating in either direction; NOTICE! however, incorrect rotation will cause high discharge temperature. KRSD series Page 18... -
Page 19: Operation
Always close the service valve when compressor is not being used. It prevents back pressure from the service line and avoids leakage due to check valve failure. NOTICE Emergency shutdown. Press the emergency stop button or pull the circuit breaker at the main power terminal. NOTICE Page 19 KRSD series... -
Page 20: Electronic Controller Basic Operation
Factory Parameters Schedule Activate Calibration Set Fault History Sequence Parameters Motor VSD Configuration Parameters Fan VSD Maintenance Parameters Date and Time Set VSD Settings Return KRSD series Page 20... - Page 21 When viewing RUN data press to scroll down to next page. When on Icon page press to move up to next row. When modifying values press to increase. When viewing RUN data press to scroll up a page. Page 21 KRSD series...
- Page 22 If activated, the following Icons will appear on the Normal Run Screen: A Time Schedule has been set. A Pressure Schedule has been set. Auto Restart is engaged. Remote Stop/Start activated. Computer Visualization set. Multi-Unit Sequence Control activated. KRSD series Page 22...
- Page 23 Discharge Temperature OO75˚C Display discharge temperature System Pressure OO.75MPa Display system pressure Oil Pressure OO.55MPa Display oil pressure differential Differential Front Rotor T OO65˚C Display front rotor temperature Rear Rotor T OO65˚C Display rear rotor temperature Page 23 KRSD series...
- Page 24 Display Motor actual RPM based on the calculation of Motor Rated Speed OOOO RPM motor frequency read Motor Rated Power OOO.O Hz Display Inverter output Frequency Motor Output Current OOO.O A Display Inverter Output Current KRSD series Page 24 Motor Output Voltage OOO.O V Display Inverter Output Voltage...
- Page 25 Display motor Total run power consumption PF Fan ɸ UI OOOOOO.OVA Display fan Real time KW PF Fan This Elec. OOO.O KW/Hr Display fan Real time power consumption PF Fan Total Elec. OOO.O KW/Hr Display fan total run power consumption Page 25 KRSD series...
- Page 26 Set to bypass Fan Motor Overload protection on start Fan Start Delay (S) OOO3 Star Delay (S) OOO6 Star Delta changeover time Load Delay (S) OOO2 Delay to load after start running in Delta Standby Delay (S) O6OO Compressor will stop after running continuously KRSD series Page 26...
- Page 27 Sleep Backlight OOO7 Turn off backlight if not in operation. Check whether the system pressure is lower than the System P Delay OO6OS set low system pressure stop value after start delay lasts for this time. Page 27 KRSD series...
- Page 28 Fan Rated Current (A) overload the set data, the unit will stop for overload. data/1.2 Discharge Temperature O105/0221 Discharge temperature alarm. Alarm (˚C/˚F) Discharge Temp trip O110/0230 Discharge Temperature Trip. (˚C/˚F) KRSD series Page 28 Front Bearing Alarm O105/0221 Drive Bearing Temperature Alarm.
- Page 29 (˚C/˚F) than the set data, it is reported temperature sensor fault and stop. Auto Restart Disable/Enable Will Restart Compressor after Power Failure if Enabled. PF Motor Power 1.72 Set to Calculate Motor Power. Coefficient Page 29 KRSD series...
- Page 30 PHASE WRONG 1 Factory Incorrect Rotation Detected. PHASE WRONG 2 Factory Loss of Phase. SENSOR FAULT Factory Temperature Sensor Disconnected or Faulty. 5.3.4 Calibration menu Press MENU, Press CALIBRATION PARA, enter the password, press Enter and Confirm. KRSD series Page 30...
- Page 31 0.00. It is used to avoid air pressure transmitter from increasing When P 2 is below this set value, the pressure is P 2 ZERO: 0002 displayed as 0.00. It is used to avoid pressure zero from increasing Page 31 KRSD series...
- Page 32 Unload when master air pressure is above this set data. Block Delay (S) OO20 Delay to Start and Load More than One Compressor. Turn Time (M) OO60 Time to Change Over Master and Slave Compressor. KRSD series Page 32 Block Mode PF – PF All Fixed compressors...
- Page 33 8 Data bits 1 Stop bit Even Parity 5.3.6 Hardware parameters Hardware parameters are used to set the function of terminals 17-24, 31, 32 and 33. MENU PRESET DATA FUNCTION 24 Terminal Emergency NO FUNCTION/EMERGENCY/REMOTE ON/REMOTE Page 33 KRSD series...
- Page 34 Air Filter Max Run Time (H) 2OOO disabled Alarm Prompt Hours. Set to OOOO and function is Lubricant Max Run Time (H) 2OOO disabled Alarm Prompt Hours. Set to OOOO and function is Grease Max Run Time (H) 2OOO disabled KRSD series Page 34...
- Page 35 Corresponding address of inverter reset command This data is inverter start data (please refer to Run Value 0001 communication chapter in inverter manual for different inverter). Corresponding register address of inverter running Freq (W) Add 2136 frequency source. Page 35 KRSD series...
- Page 36 Inverter reports error formula or not. 0000≠0000 Emergency Add 2135 Corresponding add of inverter emergency stop command. This data is inverter start data (please refer to Run Value 0001 communication chapter in inverter manual for different inverters.) KRSD series Page 36...
- Page 37 SCH WORK is Time specific and can be programmed for up to 4 scheduled on/off periods per day. When set to 0000, the function is disabled. 5.3.12 History record Select FAULT REC. Stores 100 faults in history file. Can be Reset in Factory Menu. Page 37 KRSD series...
- Page 38 RUN terminal will keep closed to control Inverter Frequency until STOP DELAY is completed. COMM ON / OFF. Start or Stop Inverter thru RS485 Inverter Start Mode Comm/terminal Terminal ON / OFF. Start or Stop Inverter through KRSD series Page 38...
- Page 39 Pressure 1 ≤ Constant Power Pressure 2 ≤ Constant 1 (Hz) Power Pressure 3 ≤ Constant Power Pressure 4 ≤ Constant Power Frequency Constant Power Pressure 4 ≤ Constant Power Pressure 160.0 2 (Hz) 5 ≤ Constant Power Pressure 6 ≤ Constant Power Page 39 KRSD series...
- Page 40 Set FAN RATED POWER to calculate the actual fan Fan Rated Power (KW) 001.5 power in FAN VSD mode. Set the corresponding fan speed in 50HZ to calculate Fan Rated Speed (RPM) 1500 actual fan speed in FAN VSD mode. KRSD series Page 40...
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Page 41: Technical Parameters
COM/TERMINAL Set fan inverter start mode. Vsd Fan Elec (Kw.H) 000000.00 VSD fan power consumption. 5.3.15 Date and Time Select DATE. Set real time and date. 5.4. Technical Parameters 1. Ambient: -20 ~ 60˚C (-4 ~ 140˚F). 2. Digital Inputs: 8. Page 41 KRSD series... - Page 42 13. RS485 port 1: For Sequence or Computer communication. 14. RS 485 port 2: For Inverter control. 15. Phase reversal protection response time ≤ 1 s. 16. High temperature response time ≤ 2 s. 17. Overload protection response time: KRSD series Page 42...
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Page 43: Alarms
Check if the coil of contactor connects with loose or controller is reset by shakes frequently RC snubber or not. interference Wrong relatively Inverter parameter of controller and Check the set data; Check the cable. Communication Fault Inverter; Communication cable loose Page 43 KRSD series... -
Page 44: Servicing
NOTICE 6.2 AIR FILTER The standard Kaishan air filter is a single stage, dry type element. Air filter maintenance should be performed when the maintenance gauge shows red with the compressor running full load, or every 4,000 hours, or once a year, whichever comes first. Daily cleaning of the filter element is common in dirty conditions. -
Page 45: Fluid Filter
The following is a sampling procedure for oil sump without fixed sampling hardware installed. Check the pressure gauge reading on reservoir and wait until there is no pressure in reservoir. The oil sample is collected by gravity drain into the sample bottle. Page 45 KRSD series... -
Page 46: Maintenance Schedule
Check for loose fluid and air tubing, electrical wiring connection. Every 1000 hours Clean air filter or replace with new element. Clean after-cooler fins. Every 2000 hours Check safety valve Replace fluid filter. Perform fluid sampling. KRSD series Page 46... - Page 47 Every 4000 hours Replace air filter. Replace air/oil separator (spin on type) Every 8000 hours Check equipment power supply and earth-grounding. Replace air/oil separator (standard type). Replace fluid. Page 47 KRSD series...
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Page 48: Troubleshooting Guide
Remove the intake hose and check the inlet valve for proper operation Defective blow-down valve Check the receiver tank to ensure that it is exhausting air to the atmosphere when the solenoid opens - repair or replace if necessary. KRSD series Page 48... - Page 49 Check and replace as necessary Proportional valve failure Check and replace as necessary Air Intake valve stuck open Remove the intake hose and check the inlet valve for proper operation Minimum pressure valve Check for leaking, replace as necessary failure Page 49 KRSD series...
- Page 50 Separator element damaged Check and replace as necessary. Oil level too high Drain off oil until the correct level. Fluid foaming Drain off oil and change Oil return line or orifice Clean and replace as necessary. clogged KRSD series Page 50...
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Page 51: Standard Terms And Conditions
Standard Terms and Conditions These terms and conditions govern the sale of Products (“Rotary Screw Air Compressors and parts”) and provisions of services by Kaishan Compressor USA,Ltd. (Seller) and its authorized representative or buyer. These terms and conditions (“Agreement”) take precedence over Buyer’s supplemental or conflicting terms and conditions to which notice... - Page 52 Seller. A delayed delivery of any part of an Order does not entitle Buyer to cancel other deliveries. Kaishan Compressor will comply with various federal, state and local laws and regulation concerning occupational health, safety and environment concerns.
- Page 53 Agreement. This Agreement is binding on successor and assigns, (c) Products, including software or other intellectual property, are subject to any applicable rights of third parties, such as patents, copyrights and/or user licenses. Page 53 KRSD series...
- Page 54 Contact Information Kaishan Compressor, LLC., Add.: 7650-A Stanton St., Daphne, AL ,Post code: 36526 Office number: +1 251-202-0577 www.KaishanUSA.com KRSD series Page 54...