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-200) PN: 96002018000001 Release: May 2018, Version: A...
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Page 2: Table Of Contents
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 Technical Parameters and functions…………………………… ………………29 Page 2 KRSD series... - Page 3 Model and specifications…………………………………………………………30 Installation………………………………………………………………………31 Alarms………………………………………………………………………….34 Controller protection…………………………………………………………….35 6. Servicing………………………………………………………………………………..38 Fluid Change……………………………………………………………..……..38 Air Filter……………………………………………………………………….…..38 Fluid Filter………………………………………………………………………..39 Air/Oil Separator………………………………………………………………….39 Fluid sampling procedure……………………………………………………….39 Maintenance Schedule…………………………………………………………….40 7. Troubleshooting Guide.………………………………………………………………42 8. Standard Terms and Conditions ……………………………………………….…..45 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: Fire And Explosion
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. Page 6 KRSD series... -
Page 7: Electrical Shock
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. -
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. Page 10 KRSD series... -
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. Page 14 KRSD series... -
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 the top red-mark is reached. Page 16 KRSD series... -
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. Page 18 KRSD series... -
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
Right / Enter: Moves the cursor when data is modified and is used as enter button when menu is selected. Escape / Reset: Serve as back button when in menu to return to the upper menu. Resetting is carried out by pressing this button for 5 seconds when in fault stop. Page 20 KRSD series... - Page 21 Press “Down” to enter into the following Menu Selection Interface: RUN PARAMETERS CALENDAR CUSTOMER PARAMETERS FACTORY PARAMETERS a. Operation Parameters Review Press “Up” or “Down” to move the black cursor to ‘OPERATING PARAMETERS’ and then press “Enter” to pop up the submenu: Page 21 KRSD series...
- Page 22 DATE AND TIME 2017 Y 2 M 12 D SUNDAY 12 H 46 M 59 S When the motor is not running, the date and time can be adjusted according to the following steps: Page 22 KRSD series...
- Page 23 The CUSTOMER PARAMETERS can be read now without pressing “Enter”. When pressing “Enter” the following interface will pop up and the password will be required (9999). NOTE: Customer Password can be modified in the CUSTOMER PARAMETER menu. Page 23 KRSD series ENTER PASSWORD ****...
- Page 24 UNLOAD P. *.**Mpa Unload pressure setting. Fan will start if discharge temperature is FAN START T. *** ˚C above this setting. This value will be set as “120 ˚C (248 ˚F)” if there is no fan Page 24 KRSD series...
- Page 25 Machine cannot be restarted before this START DELAY 0100S set time after stopped or over time operation unloaded. STANDBY DELAY 0000S Additional functions. TIME Continuous draining time during the DRAIN OPEN TIME 0002S automatic draining control. Page 25 KRSD series...
- Page 26 Reset the running time of the O/A O/A FILTER RESET 0000H MAINTENANCE Separator. PARAMETER AIR FILTER RESET 0000H Reset the running time of the air filter. RESET Reset the running time of the Lubrication LUBE OIL RESET 0000H Oil. Page 26 KRSD series...
- Page 27 **** Customer can modify the user password. MODIFICATION d）Factory parameters The FACTORY PARAMETERS cannot be modified unless you have the manufacturer password Modification procedure for the FACTORY PARAMETERS is the same as for the CUSTOMER PARAMETERS. Page 27 KRSD series...
- Page 28 0000, the low voltage function is disabled. FREQ SEL Set the power frequency. If the Warning time for oil filter, air filter, separator. ALARM STOP 0000H Lubricant or grease is over this setting, compressor reports DELAY "warning too long" and stops. Page 28 KRSD series...
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Page 29: Technical Parameters And Functions
Unbalance protection: When current difference of any two phase reach the set value, operation time equals set time. Overload protection: Operates with a time delay according to overload factors and operation time shown in the following table: Page 29 KRSD series... -
Page 30: Model And Specifications
11. RS485 communication. 5.4. Model and specifications 1. Model description MAM- KY02 S (40)（B）(T） （VIII） Control method With RS485 communication switch B: Pressure sensor; K: Pressure Motor maximum rated current Screw air compressor Air compressor controller Product series Page 30 KRSD series... -
Page 31: Installation
Transducers shall be installed where motor line current (rated current) can be measured, thus controller can be set according to data in motor’s name plate, the detailed dimensions are as follows: Figure 2. Dimensions of CT1 (ф36 through hole). Figure 3. Installation dimensions of CT1. Page 31 KRSD series... - Page 32 Output LED (OUT) 00, 01, 02, 03, 04, 05, 06, correspond to the output switching value terminals 27, 28, 29, 30, 31, 35, 36, 37, 38 and 39. PWR: Power indicator RUN: Run indicator ERR: Error indicator Page 32 KRSD series...
- Page 33 3. Control panel installation Figure7. Control panel dimensions. 3. Terminal arrangement schematic Page 33 KRSD series...
- Page 34 43, 44 220 V There are five connection cables and one communication cable which are used for display connection, RS-485 communication and 24V power supply. NOTE: Electromagnetism coil shall be connected with surge absorber during wiring. Page 34 KRSD series...
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Page 35: Alarms
Displays “GREASE TIME END” when the running time of the grease terminates. 6. High discharge temperature alarm. Displays “DISC T HIGH” when the discharge temperature is higher than the ALARM DISC T set in the FACTORY PARAMETERS menu. 5.7. Controller protection Page 35 1. Motor protection KRSD series... - Page 36 When pressure sensor or temperature sensor is disconnected, the controller cannot start the compressor. The fault is displayed as “**SENSOR FAULT”. 6. Open phase protection. When an open phase is detected, the controller cannot start the compressor. The fault is displayed as “PHASE WRONG2”. Page 36 KRSD series...
- Page 37 PROD DATE, SERIAL THIS FAULT Go to THIS FAULT, press “Enter” and the fault information will appear: STOP: DISC T SENSOR FAULT 170˚ User can reset the fault according to the information prompted. 2. Common faults and causes Page 37 KRSD series...
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Page 38: Servicing
6.1 FLUID CHANGE KRSD series compressors utilize a pressurized fluid drain. Use the following procedure to drain and replace the compressor fluid. i.Press the emergency stop button and remove the right side cabinet panel (if applicable). -
Page 39: Air Filter
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 40: Fluid Sampling Procedure
Avoid overfilling the sample bottle. Fill sample bottle up to above 80% but below the threads of the bottle. Seal the bottle tightly, wipe clean. Pre-label or label sample bottle immediately after filling to avoid mix-ups. Make sure bottles are labelled with full sample details. Page 40 KRSD series... -
Page 41: Maintenance Schedule
Check safety valve Replace fluid filter. Perform fluid sampling. 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 41 KRSD series... -
Page 42: 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. Page 42 KRSD series... - Page 43 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 43 KRSD series...
- Page 44 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 Page 44 KRSD series...
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Page 45: 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 46 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 47 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 47 KRSD series...
- Page 48 Contact Information Kaishan Compressor, LLC., Add.: 7650-A Stanton St., Daphne, AL ,Post code: 36526 Office number: +1 251-202-0577 www.KaishanUSA.com Page 48 KRSD series...