Related Manuals for Kaishan KRSL Series
Summary of Contents for Kaishan KRSL Series
- Page 1 Kaishan Rotary Screw Air Compressor KRSL Series Instruction Manual Direct Drive PN: 96002018000001 Release: August 2022, Version: B (USA)
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Page 2: Table Of Contents
4.1 COMPRESSOR MOUNTING, SUPPORT AND LOCATION ............15 4.2 VENTILATION AND COOLING ...................... 15 4.3 PIPING CONNECTION ........................16 4.4 FLUID LEVEL INSPECTION ......................17 4.5 ELECTRICAL ........................... 18 4.6 MOTOR ROTATION INSPECTION ....................18 4.7 FAN ROTATION INSPECTION ....................... 19 KRSL series Page 2... - Page 3 6.2 AIR FILTER ............................34 6.3 FLUID FILTER ..........................35 6.4 AIR/OIL SEPARATOR ........................35 6.5 FLUID SAMPLING PROCEDURE ....................35 6.6 MAINTENANCE SCHEDULE ......................36 Troubleshooting Guide ....................36 Standard Terms and Conditions ................. 40 Contact Information ....................43 Page 3 KRSL series...
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Page 4: Safety Information
Safety Information Thank you for choosing the KRSL Series Compressor. Please read this instruction manual carefully before using the compressor. This manual must be kept in the safe place for future reference. Kaishan USA authorized distributors provide maintenance service for KRSL series rotary screw compressors. -
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 KRSL series rotary screw air compressors. The owner and operator shall read this manual carefully. Only after thorough understanding should the machine be operated for the first time. -
Page 6: Moving Parts
Federal, State, and Local codes, standards and regulations. Never assume it is safe to work on the compressor because it is not operating. Many installations have automatic start/stop controls and the compressor may start at any time. KRSL series Page 6... - 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 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 KRSL series offer models with power ranging from 30 hp to 200 hp (22 kw to 150 kw)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
2.3 MOTOR The main motor is a variable speed induction motor. Operating conditions of the variable speed motor are as follows (may vary with different countries). Ambient temperature ≤40℃ Altitude ≤1000m Page 9 KRSL series... -
Page 10: Compressor Lubrication And Cooling System
2.5 COMPRESSOR DISCHARGE SYSTEM Air/fluid mixture is forced into reservoir after compression. The reservoir has two basic functions: • It acts as a primary fluid separator. KRSL series Page 10... - Page 11 7psig and 15psig (0.5Bar and 0.7Bar) during unloading conditions. The minimum pressure check valve of KRSL units assures the reservoir maintains a minimum pressure between 15psig and 25psig (1Bar and 1.7Bar) during unloading conditions. This pressure is necessary for air/fluid separation and fluid circulation. Page 11 KRSL series...
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Page 12: 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. SKY air end inlet valve Casing for air filter KRSL series Page 12... -
Page 13: Fluid Information
Fluid Information 3.1 FLUID GUIDE KRSL 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 14: Installation
Delta P Delta P Every 4,000 hours Every 2,000 hours Every 8,000 hours KTL4000 FG or as indicated by or as indicated by or as indicated by sampling report Delta P Delta P Installation KRSL series Page 14... -
Page 15: Compressor Mounting, Support And Location
Compressor must be equipped with high-ambient option if operating temperature exceeds 40°C (104°F). NOTICE! Do not install and operate compressor if the ambient temperature is below 5°C (41°F). Pre-heat option must be installed with the unit for lower ambient temperatures. NOTICE! Page 15 KRSL series... -
Page 16: Piping Connection
A union connector must be installed after the ball valve (quarter turn, shut off valve) at the compressed air outlet. This will allow unit isolation for maintenance. KRSL series Page 16... -
Page 17: Fluid Level Inspection
Inspect the fluid level when the compressor is in shut down mode to make sure fluid has not leaked from the unit during transport. Fluid level is indicated on the reservoir sight glass. When the compressor is running, the level should not exceed the top red mark on the sight glass Page 17 KRSL series... -
Page 18: 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 protection, as paint and corrosion build-up may exist. -
Page 19: 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 19 KRSL series... -
Page 20: Compressor Controller Operation
Factory Parameters Schedule Activate Calibration Set Fault History Sequence Parameters Motor VSD Configuration Fan VSD Parameters Date and Time Set Maintenance Parameters Return VSD Settings KRSL series Page 20... - Page 21 When viewing RUN data press to scroll down to the next page. When on Icons page press to move up to the next row. When modifying values press to increase. When viewing RUN data press to scroll up a page. Page 21 KRSL 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. KRSL series Page 22...
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Page 23: Program Structure
Compressor serial number Drain Close Time (S) 0060 Time set for Condensate Drain to stay closed A: 000.0A Motor current B: 000.0A Display motor current C: 000.0A A: 000.0A Fan current Display Fan current B: 000.0A Page 23 KRSL series... - Page 24 000.0 KW/Hr Display Power Consumption in Real Time Consumption Motor Power Total 000.0 KW/Hr Display accumulative Power Consumption Consumption Motor State 0000 Motor Running Status From Inverter data read Description KRSL series Page 24 Error Description 0000 Motor Error Status from Inverter data read...
- Page 25 000.0 KW/Hr Display motor Total run power consumption PF Fan ɸ UI 0000.0VA Display fan Real time KW PF Fan This Elec. 000.0 KW/Hr Display fan Real time power consumption PF Fan Total Elec. 000.0 KW/Hr Display fan total run power consumption Page 25 KRSL series...
- Page 26 LOAD DELAY TIME Fan Start Delay 0003 Set to bypass Fan Motor Overload protection on start up Star Delay 0006 Star Delta changeover time Load Delay 0002 Delay to load after start running in Delta KRSL series Page 26...
- Page 27 Turn off backlight if not in operation. Check whether the system pressure is lower than the set System P Delay 0060S low system pressure stop value after start delay lasts for this time. To change a setting: Page 27 KRSL series...
- Page 28 Press MENU, Press BLOCK PARA, enter the User password, press Enter and Confirm. MAM 6090 has the capacity to control 16 compressors via a daisy chain RS485 series link utilizing RS485-1 terminals A1, B1 and GND1. MENU DEFAULT FUNCTION KRSL series Page 28...
- Page 29 Stopping the Master compressor manually will deactivate the BLOCK Control. Network Connection: The MAM 6090 Controller supports MODBUS RTU protocol. It supports 03, 06, 16 MODBUS commands. Communication baud rate 9600 BPS 1 Start bit Page 29 KRSL series 8 Data bits...
- Page 30 OIL BLOCK Oil filter alarm Maintenance OIL TIME END Digital # 20 O/A BLOCK Separator alarm Maintenance O/A TIME END Lubricant alarm Maintenance LUBE TIME END Grease alarm Maintenance GREASE TIME END 5.2.5 Touch screen calibration KRSL series Page 30...
- Page 31 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. 5.2.8 History record Select FAULT REC. Stores 100 faults in history file. Can be Reset in Factory Menu. 5.2.9 Date and Time Page 31 KRSL series...
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Page 32: Technical Data
12. Pressure Transducer: 0 ~ 16 bar (0~232PSI), 4-20mA, 28VDC. 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. KRSL series Page 32... -
Page 33: Throubleshooting
RC snubber or not. Wrong set of relatively Inverter parameter of controller and Communication Check the set data; Check the cable. Inverter; Communication cable Fault loose Servicing Page 33 KRSL series... -
Page 34: Fluid Change
NOTICE 6.2 AIR FILTER The standard Kaishan air filter is a single stage, dry type element. Air filter maintenance should be performed by the the maintenance gauge shows red with the compressor running full load, or every 4000 hours, or once a year, whichever comes first. Daily cleaning of the filter element is common in dirty conditions. -
Page 35: Fluid Filter
Collect oil, avoid overfilling the sample bottle. Close the sample valve. Seal the bottle tightly, wipe clean. vii. Pre-label or label sample bottle immediately after filling to avoid mix-ups. Make sure bottles are labelled with full sample details. Page 35 KRSL series... -
Page 36: Maintenance Schedule
Check equipment power supply and earth-grounding. Every 8000 hours Replace air/oil separator. Replace fluid. Troubleshooting Guide Information below is a troubleshooting guideline; it describes symptoms and possible cause. Do not assume that these are the only faulty condition that may occur. KRSL series Page 36... - Page 37 Loose wiring connection Check and tighten wiring terminals does not Faulty proportional Orifice plugged. Clean or replace as reload when valve necessary service line Jammed air inlet valve Check and repair air inlet valve pressure drops assembly Page 37 KRSL series...
- Page 38 Plugged air/oil separator Check and replace as necessary working Air Intake valve stuck Remove the intake hose and check the inlet pressure, open valve for proper operation causing safety KRSL series Page 38 Safety valve failure Repair or replace as necessary...
- Page 39 Check and replace as necessary. damaged Fluid Oil level too high Drain off oil until the correct level. Consumption Fluid foaming Drain off oil and change Oil return line or orifice Clean and replace as necessary. clogged Page 39 KRSL series...
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Page 40: 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 (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 of objection is hereby given. - Page 41 Seller. A delayed delivery of any part of an Order does not entitle Buyer to cancel other deliveries. Kaishan Compressor USA will comply with various federal, state and local laws and regulation concerning occupational health, safety and environment concerns.
- Page 42 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. KRSL series Page 42...
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Page 43: Contact Information
Contact Information Kaishan Compressor, LLC., Add.: 15445 Industrial Park Dr., Loxley, AL, Post code: 36551 Office number: +1 251-202-0577 Page 43 KRSL series...
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