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KAESER
Compressor
BSD 40
KAESER BSD 40 User Manual
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Description
Function
18
IDLE
Lights green when the compressor is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
19
Machine ON
Lights green when the machine switched on.
20
Clock
The LED lights when the machine is in clock control.
21
Remote control
The LED lights when the machine is in remote control.
Tab. 39
Indicators
4
Design and Function
4.7
SIGMA CONTROL Keys and Indicators
9_5708 08 USE
Service Manual Screw Compressor
BSD
33
42
44
Table of Contents
Default Chapter
3
Table of Contents
3
1 Regarding this Document Using the Document
11
Further Documents
11
Copyright
11
Symbols and Identification
11
Warnings
11
Other Instructions and Symbols
12
Tab. 1 the Levels of Danger and Their Meaning
12
2 Technical Data Nameplate
13
Options
13
Tab. 2 Nameplate
13
Weight
14
Temperature
14
Ambient Conditions
14
Tab. 3 Options
14
Tab. 4 Machine Weight
14
Tab. 5 Temperature
14
Tab. 6 Ambient Conditions
14
Ventilation
15
Pressure
15
Fig. 1 Maximum Relative Humidity
15
Tab. 7 Ventilation
15
Tab. 8 Safety Relief Valve Setting
15
Delivery
16
Cooling Oil Recommendation
16
Basic Information
16
KAESER Lubricants
16
Tab. 9 Delivery
16
Cooling Oil Charge
17
Tab. 10 Cooling Oil Charge (Option K1)
17
Tab. 11 Cooling Oil Charge (Option K2)
17
Motors and Power
18
Drive Motor
18
Fan Motor
18
Tab. 12 Cooling Oil Charge (Option W1)
18
Tab. 13 Cooling Oil Charge (Option W2)
18
Tab. 14 Cooling Oil Charge (Option W3)
18
Tab. 15 Drive Motor
18
Fan Motor
19
Sound Pressure Level
19
Power Supply
19
Tab. 16 Fan Motor (Option K1)
19
Tab. 17 Fan Motor (Option K2)
19
Tab. 18 Sound Pressure Level
19
Power Supply Specifications
20
Tab. 19 Supply 208V/3/60Hz
20
Tab. 20 Connection Details 230V/3/60Hz
20
Water-Cooling
21
Design Data
21
Tab. 21 Connection Details 380V/3/60Hz
21
Tab. 22 Connection Details 460V/3/60Hz
21
Tab. 23 Supply 575V/3/60Hz
21
Cooling Water Quality
22
Tab. 24 Cooling Water Temperature (ΔT=20°F)
22
Tab. 25 Cooling Water Temperature (ΔT=50°F)
22
Tab. 26 Cooler Specification (Option K2)
22
Heat Recovery
23
Prepared for External Heat Recovery
23
Internal Heat Recovery
23
Tab. 27 Cooling Water Quality
23
3 Safety and Responsibility Basic Information
26
Specified Use
26
Improper Use
26
User's Responsibilities
26
Observe Statutory and Universally Accepted Regulations
26
Qualified Personnel
27
Adhere to Inspection Schedules and Accident Prevention Regulations
27
Dangers
27
Safely Dealing with Sources of Danger
28
Safe Machine Operation
30
Organizational Measures
30
Danger Areas
30
Safety Devices
31
Safety Signs
31
Tab. 34 Danger Areas
31
Fig. 2 Location of Safety Signs
32
Emergencies
33
Correct Fire Fighting
33
Tab. 35 Safety Signs
33
Remove any Cooling Oil from Your Person
34
Warranty
34
Environmental Protection
34
4 Design and Function
35
Enclosure
35
Functional Description of the Machine
35
Fig. 3 Enclosure Overview
35
Floating Relay Contacts
36
Fig. 4 Machine Layout
36
Options
37
Machine Mountings
37
Cooling Air Filter Mat
37
Water-Cooling
37
Fig. 5 Machine Mountings
37
Fig. 6 Cooling Air Filter Mat (Option K3)
37
Heat Recovery
38
Fig. 7 Water-Cooling (Option K2)
38
Operating Modes and Control Modes
39
Operating Modes
39
Control Modes
39
Fig. 8 Internal Heat Recovery (Option W2/W3)
39
Tab. 36 Energy-Efficient Control Modes
40
Safety Devices
41
SIGMA CONTROL Keys and Indicators
41
Fig. 9 Keys
41
Tab. 37 Operating Modes under MODULATING Control
41
Fig. 10 Indicators
42
Tab. 38 Keys
42
Tab. 39 Indicators
43
5 Installation and Operating Conditions
44
Safety
44
Installation Conditions
44
Determining Location and Clearances
44
Ensure Adequate Ventilation
45
Exhaust Duct Design
45
Fig. 11 Recommended Machine Placement and Dimensions [MM]
45
Using the Compressor to Supply a Compressed Air System
46
6 Installation Safety
47
Reporting Transport Damage
47
Making the Compressed Air Connection
47
Making the Power Supply Connection
48
Fig. 12 Compressed Air Connection
48
Options
49
Anchoring the Machine
49
Connecting the Cooling Water
49
Fig. 13 Connecting the Cooling Water
49
Connecting the Heat Recovery System
50
Fig. 14 Connecting the Heat Recovery System
51
7 Initial Start-Up Safety
52
To be Noted before Commissioning
52
Checking Installation and Operating Conditions
53
Tab. 40 Re-Commissioning after Storage
53
Setting the Overload Protection Cut-Out
54
Setting the Motor Overload Protection Switch
54
Filling Cooling Oil into the Airend
54
Tab. 41 Installation and Operating Conditions Checklist
54
Checking Direction of Rotation
55
Fig. 15 Inlet Valve Filling Port
55
Fig. 16 Coupling
55
Starting the Machine for the First Time
56
Setting the Setpoint Pressure
56
Changing the Display Language
56
Fig. 17 Label: Changing the Display Language
57
8 Operation
58
Switching on and off
58
Switching on
58
Shutdown
58
Fig. 18 Switching on and off
58
Switching off in an Emergency and Switching on Again
59
Switching on and off from a Remote Control Center
59
Fig. 19 Switching off in an Emergency
59
Switching on and off with the Clock
60
Fig. 20 Switching on and off from a Remote Control Center
60
Tab. 42 Machine Identification
60
Tab. 43 Remote Control Identification
60
Acknowledging Alarm and Warning Messages
61
Fig. 21 Switching on and off with the Clock
61
Tab. 44 Machine Identification
61
Fig. 22 Acknowledging Messages
62
9 Fault Recognition and Rectification
63
Basic Information
63
Alarm Messages (Machine Stop)
63
Warning Messages (Yellow LED Lights)
66
Other Faults
70
Tab. 46 Warning Messages
70
Tab. 47 Other Faults and Actions
71
10 1 Maintenance
72
Safety
72
Maintenance Schedule
73
Logging Maintenance Work
73
Resetting Maintenance Interval Counters
73
Regular Maintenance Tasks
73
Cooling Oil Changing Interval
74
Tab. 48 Regular Maintenance Tasks
74
Regular Service Tasks
75
Cleaning or Renewing the Cooling Air Filter Mat
75
Cleaning or Replacing the Control Cabinet Filter Mats
76
Fig. 23 Cooling Air Filter Mat
76
Cooler Maintenance
77
Fig. 24 Control Cabinet Ventilation Grill
77
Water-Cooling Maintenance
78
Fig. 25 Cleaning the Cooler
78
Maintain the Heat Recovery System
79
External Heat Recovery System
79
Internal Heat Recovery
79
Air Filter Maintenance
79
Motor Maintenance
80
Fig. 26 Air Filter Maintenance
80
Checking the Coupling
81
Fig. 27 Drive Motor Maintenance
81
Checking the Safety Relief Valve
82
Fig. 28 Checking the Coupling
82
Checking the Overheating Safety Shutdown Function
83
Checking the Cooling Oil Level
83
Venting the Machine (Depressurizing)
84
Fig. 29 Checking the Cooling Oil Level
84
Fig. 30 Venting the Machine
85
Topping up the Cooling Oil
86
Venting the Machine (Depressurizing)
86
Fig. 31 Topping up the Cooling Oil
86
Top up with Cooling Oil and Test Run
87
Changing the Cooling Oil
88
Fig. 32 Changing the Cooling Oil, Oil Separator Tank
89
Fig. 33 Changing the Cooling Oil, Oil Cooler
90
Fig. 34 Changing the Cooling Oil, Airend
91
Fig. 35 Changing the Cooling Oil, Oil Tank
92
Changing the Oil Filter
93
Fig. 36 Changing the Cooling Oil, Heat Recovery System
93
Changing the Oil Separator Cartridge
94
Fig. 37 Changing the Oil Filter
94
Fig. 38 Changing the Oil Separator Cartridge
95
Document Maintenance and Service Work
97
Tab. 51 Logged Maintenance Tasks
97
11 Spares, Operating Materials, Service
98
Note the Nameplate
98
Ordering Consumable Parts and Operating Fluids/Materials
98
Kaeser Air Service
98
Tab. 52 Consumable Parts
98
Service Addresses
99
Spare Parts for Service and Repair
99
12 Decommissioning, Storage and Transport
104
Putting out of Operation
104
Packing
104
Storage
104
Transporting
105
Safety
105
Transporting with a Forklift
105
Transporting with a Crane
105
Fig. 39 Transporting with a Forklift
105
Disposal
106
Fig. 40 Transporting with a Crane
106
13 Annex
107
Pipeline and Instrument Flow Diagram (P+I Diagram)
107
Pipe and Instrument Flow Diagram (P+I Diagram): MODULATING Control Mode
113
Dimensional Drawing
119
Electrical Diagram
123
4
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KAESER BSD 40 Specifications
General
Brand
KAESER
Model
BSD 40
Category
Compressor
Language
English
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