KAESER KOMPRESSOREN CSG-2 SFC W Manuals

Manuals and User Guides for KAESER KOMPRESSOREN CSG-2 SFC W. We have 1 KAESER KOMPRESSOREN CSG-2 SFC W manual available for free PDF download: Operator's Manual

KAESER KOMPRESSOREN CSG-2 SFC W Operator's Manual (190 pages)

Screw Compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 21 MB

Table of Contents
3
Regarding this Document Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definition (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
Technical Data Nameplate
14
Options
14
Tab. 3 Nameplate
14
Weight
15
Temperature
15
Tab. 4 Options
15
Tab. 5 Weight
15
Tab. 6 Temperature
15
Ambient Conditions
16
Ventilation
16
Tab. 7 1St Stage Airend - Airend Temperature
16
Tab. 8 2Nd Stage Airend - Airend Temperature
16
Tab. 9 Ambient Conditions
16
Pressure
17
Flow Rate (Constant Delivery Volume Relative to Intake Conditions)
17
Tab. 10 Ventilation
17
Tab. 11 1St Stage Safety Relief Valve Activating Pressure
17
Tab. 12 2Nd Stage Safety Relief Valve Activating Pressure
17
Rated Voltage 380V / 3 / 60Hz
18
Fig. 1 Flow Rate and Control Range
18
Tab. 13 Flow Rate 380 V / 145 Psig
18
Rated Voltage 460 V / 3 / 60 Hz
19
Tab. 14 Flow Rate 380 V / 145 Psig
19
Tab. 15 Flow Rate 380 V / 90 Psig
19
Tab. 16 Flow Rate 460 V / 145 Psig
19
Cooling Oil Recommendation (Gear)
20
Tab. 17 Flow Rate 460 V / 145 Psig
20
Tab. 18 Flow Rate 460 V / 90 Psig
20
Cooling Oil Charge (Gearbox)
21
Tab. 19 Cooling Oil Recommendation
21
Tab. 20 Cooling Oil Recommendation (Food Processing)
21
Tab. 21 Cooling Oil Charge
21
Motors and Power
22
Tab. 22 Motor Data, Compressor Motor
22
Tab. 23 Motor Data, Fan Motor
22
Sound Emission
23
Water Systems
23
Tab. 24 Sound Emission
23
Tab. 25 Water System Requirements
25
Tab. 26 Water Quality
27
Tab. 27 Oil Cooling Heat Exchanger Specifications
27
Heat Recovery
28
Tab. 28 Heat Exchanger Specifications, Stage 1 and Stage 2 (Primary Water System)
28
Tab. 29 Heat Exchanger Specifications (Secondary Water System)
28
Power Supply
29
Tab. 30 Individual Design Data
29
Tab. 31 Heat Capacity for Heating from 113°F to 158°F
29
Tab. 32 Flow Rate for Heating from 113°F to 158°F
29
Power Supply Specifications
30
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral
30
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral
30
Tab. 33 Power Supply Details 380V/3/60Hz
30
Tab. 34 Power Supply Details 460V/3/60Hz
31
Safety and Responsibility Basic Instructions
32
Specified Use
32
Improper Use
32
User's Responsibilities
32
Observe Statutory and Universally Accepted Regulations
32
Qualified Personnel
33
Complying with Inspection Schedules and Accident Prevention Regulations
33
Dangers
33
Safely Dealing with Sources of Danger
34
Safe Machine Operation
36
Organizational Measures
38
Danger Areas
38
Safety Devices
38
Tab. 35 Danger Areas
38
Service Life of Safety Functions
39
Safety Signs
39
Fig. 4 Location of Safety Signs Outside
40
Fig. 5 Location of Safety Signs Front Side
42
Tab. 36 Safety Signs Outside
42
Fig. 6 Location of Safety Signs Rear Side
43
Tab. 37 Safety Signs Front Side
43
Fig. 7 Location of Safety Signs with W5 Option
44
Tab. 38 Safety Signs Rear Side
44
Tab. 39 Safety Signs with W5 Option
44
Emergency Situations
45
Correct Fire Fighting
45
Fig. 8 Location of Safety Signs in the Control Cabinet
45
Tab. 40 Safety Signs Control Cabinet
45
Treating Injuries from Handling Cooling Oil
46
Warranty
46
Environmental Protection
47
Design and Function
48
Enclosure
48
Machine Function
48
Fig. 9 Enclosure Overview
48
Fig. 10 Machine Overview (View 1)
50
Water System Functionality
51
Fig. 11 Machine Overview (View 2)
51
Fig. 12 Primary Water System (Schematic Diagram)
53
Fig. 26 Control Valve
53
Fig. 13 Primary and Secondary Water System (Schematic Diagram)
56
Fig. 14 Options for the Primary and Secondary Water System (Schematic Diagram)
57
Frequency Converter
58
Tab. 41 Oil Cooling in Primary or Secondary Water System
58
Tab. 42 Airend Cooling in Primary or Secondary Water System
58
Tab. 43 Connection Options for Option K10
58
Floating Contacts
59
Safety Devices
59
Operating Panel SIGMA CONTROL
60
Fig. 15 Keys - Overview
60
Tab. 44 Keys
60
Fig. 16 Indicators - Overview
61
Tab. 45 Indicators
61
Machine Operating Modes
62
Fig. 17 RFID Reader
62
Tab. 46 RFID Reader
62
Frequency-Controlled Drive (SFC)
63
Options
63
Controller SIGMA CONTROL 2: Connection to Control Technology
63
Machine Mountings
64
Hot-Air Outlet with Regulation
64
Fig. 18 Machine Mountings
64
Tab. 47 Components
64
Auxiliary Heat Exchanger, Second Stage: Plate-Type Heat Exchanger
65
Fig. 19 Conceptual Sketch (Flow Diagram)
65
Heat Recovery
66
Fig. 20 Internal Heat Recovery System (HRS) with Water Pump
66
Installation and Operating Conditions
70
Ensuring Safety
70
Installation Conditions
70
Determining Location and Clearances
70
Ensuring Adequate Machine Room Ventilation
71
Fig. 21 Recommended Installation, Dimensions [In.]
71
Inlet and Exhaust Air Ducting
72
Using the Compressor to Supply a Compressed Air System
72
Installation
73
Ensuring Safety
73
Reporting Transport Damage
74
Connecting the Machine with the Compressed Air Network
74
Connecting the Power Supply
75
Fig. 22 Compressed Air Connection
75
Connecting the External Pressure Transducer
76
Connecting the Water-Cooling
76
Fig. 23 Connecting the Water-Cooling (Secondary Water System with Option W5/W6)
77
Fig. 25 Connecting the Water-Cooling (Primary Water System)
78
Connecting a User-End Water Pump
79
Control Valve in the Primary Water System: V14
79
Connecting the Heat Recovery to the Primary Water System
80
Fig. 27 Control Valve
80
Connecting the Internal Heat Recovery
81
Fig. 28 Connecting the Heat Recovery System
81
Fig. 29 Control Valve
81
Connecting a User-End Water Pump or Stop Valve
82
Connecting the Condensate Drain
82
Tab. 48 Condensate Line
83
Tab. 49 Condensate Collecting Line
83
Tab. 50 Condensate Collecting Line: Line Cross-Section
83
Options
84
Anchoring the Machine
84
Fig. 30 Connecting the Condensate Drain
84
Initial Start-Up Ensuring Safety
85
Instructions to be Observed before Commissioning
86
Checking Installation and Operating Conditions
86
Tab. 51 Recommissioning after Storage
86
Commissioning the Frequency Converter
87
Setting the Motor Overload Protection Relay
87
Tab. 52 Installation Conditions Checklist
87
Checking the Direction of Rotation
88
Starting the Machine for the First Time
88
Setting the Display Language
88
Setting the Set Point Pressure
89
Setting Water Systems
89
Fig. 31 Setting the Water System for Cooling of the Airends
90
Fig. 32 Setting the Water System for Cooling the Cooling Oil
90
Operating the Machine Without Heat Recovery System
91
Cooling the Machine with the Primary Water System
91
Cooling the Machine with the Secondary Water System
91
Cooling the Machine with the Secondary Water System
92
Hot Air Outlet with Regulation
92
Operation
93
Switching on and off
93
Switching on
93
Fig. 33 Switching on and off
93
Switching off
94
Switching off in an Emergency and Switching on Again
94
Fig. 34 Switching off in an Emergency
94
Switching on and off from a Remote Control Center
95
Switching on and off with the Shift Clock
95
Fig. 35 Switching on and off from a Remote Control Center
95
Tab. 53 Machine Identification
95
Tab. 54 Remote Control Identification
95
Interpreting Operation Messages
96
Acknowledging Alarm and Warning Messages
96
Fig. 36 Switching on and off with the Shift Clock
96
Tab. 55 Machine Identification
96
Fig. 37 Acknowledging Messages
97
Fault Recognition and Rectification
98
Basic Instructions
98
Other Faults
98
Tab. 56 Other Faults and Remedies
99
10 Maintenance
100
Ensuring Safety
100
Tab. 57 Advise Others that the Machine Is Being Serviced
100
Maintenance Schedule
101
Logging Maintenance Work
101
Resetting Maintenance Interval Counters
101
Regular Maintenance Tasks
102
Cooling Oil: Change Interval
103
Regular Maintenance Tasks
103
Checking the Machine for Leaks
104
Air Filter Maintenance
104
Tab. 60 Regular Service Tasks
104
Replacing the Prefilter
105
Replacing the Air Filter
105
Fig. 38 Replacing the Prefilter
105
Control Cabinet: Clean or Replace the Filter Mats
106
Fig. 39 Replacing the Air Filter (Incl. Prefilter)
106
Fig. 40 Switching Cabinet Ventilation
107
Machine Ventilation: Clean or Replace the Filter Mats
108
Fig. 41 Cleaning the Filter Mats
108
Cleaning the Heat Exchanger
109
Motor Maintenance
109
Checking the Coupling
110
Fig. 42 Motor Maintenance
110
Fig. 43 Checking the Coupling
111
Checking the Overheating Safety Shutdown Function
112
Check the EMERGENCY STOP Push Button
112
Testing the Safety Relief Valves
112
Fig. 44 Check the EMERGENCY STOP Push Button
112
Checking Cooling Oil Level and Replenishing Cooling Oil (Gear)
113
Fig. 45 Checking the Cooling Oil Level
114
Changing the Cooling Oil (Gear)
115
Fig. 46 Replenish Cooling Oil
115
Fig. 47 Draining Cooling Oil from the Transmission Pan
116
Fig. 48 Draining the Cooling Oil from the Heat Exchanger for Oil Cooling
117
Changing the Oil Filter
118
Fig. 49 Filling with Cooling Oil
118
Compressed Air Filter: Changing the Filter Element for Gear Ventilation
119
Fig. 50 Changing the Oil Filter
119
Removing the Filter Element
120
Fig. 51 Removing the Filter Element
120
Installing the Filter Element
121
Fig. 52 Installing the Filter Element
121
Installing the Filter Bowl
122
Fig. 53 Installing the Filter Bowl
122
Fig. 54 Amend the Maintenance Sticker
122
Venting the Machine (Depressurizing)
123
Fig. 55 Venting the Machine
123
Condensate Drain Maintenance
124
Checking the Condensate Drain Downstream from Stage 1
124
Fig. 56 Checking the Condensate Drain
124
Checking the Condensate Drain Downstream from Stage 2
125
Replacing the Service Unit
125
Fig. 57 Checking the Condensate Drain
125
Fig. 58 Replacing the Service Unit
126
Changing the Control Air Filter
127
Fig. 59 Changing the Control Air Filter
127
Documenting Maintenance and Service Work
129
Tab. 61 Logged Maintenance Tasks
129
11 Spares, Operating Materials, Service
130
Note the Nameplate
130
Ordering Spare Parts and Operating Fluids/Materials
130
Tab. 62 Spare Parts
130
Kaeser Air Service
131
Replacement Parts for Service and Repair
131
12 Decommissioning, Storage and Transport
138
Decommissioning
138
Packing
139
Storage
139
Transporting
140
Safety
140
Transport with a Forklift Truck
140
Transport with a Crane
140
Fig. 60 Transport with a Forklift Truck
140
Fig. 61 Transport with a Crane
141
Disposal
142
Dispose of the Machine in Accordance with Local Environmental Regulations
142
Battery Disposal in Accordance with Environmental Guidelines
142
Fig. 62 Battery Labelling
142
13 Annex
143
Pipeline and Instrument Flow Diagram (P+I Diagram)
143
Dimensional Drawing
151
Electrical Diagram
154
Electrical Diagram
160
Common Parts
163

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