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KAESER
Compressor
SK Series
KAESER SK Series User Manual
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Operating Manual
Rotary screw compressor
SK
901848 21 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 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 Alert Notes and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
2 Technical Specifications Nameplate
14
Options
14
Tab. 3 Nameplate
14
Tab. 4 Options
14
Mass
15
Temperature
15
Ambient Conditions
15
Tab. 5 Mass
15
Tab. 6 Temperature
15
Tab. 7 Ambient Conditions
15
Ventilation
16
Pressure
16
Fig. 1 Maximum Relative Humidity of Intake Air
16
Tab. 8 Overview Ventilation (50Hz)
16
Tab. 9 Overview Ventilation (60Hz)
16
Flow Rate (Constant Delivery Volume Relative to Intake Conditions)
17
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
17
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
17
Tab. 12 Flow Rate (50Hz)
17
Tab. 13 Flow Rate (60 Hz)
17
Cooling Oil Recommendation
18
Tab. 14 Cooling Oil Recommendation
18
Cooling Oil Charge
19
Tab. 15 Cooling Oil Recommendation (Food Processing)
19
Tab. 16 Cooling Oil Recommendation (Machines for Snow Cannons)
19
Tab. 17 Cooling Oil Charge (Option K1)
19
Motors and Power
20
Compressor Drive Motor
20
Noise Emission [Db(A)]
20
Tab. 18 Cooling Oil Charge (Option W1)
20
Tab. 19 Compressor Drive Motor
20
Tab. 20 Compressor Drive Motor: Rated Speed for 50 Hz
20
Tab. 21 Compressor Drive Motor: Rated Speed for 60 Hz
20
Electrical Connection
21
Power Supply Specifications
21
Tab. 22 Noise Emission [Db(A)]
21
Mains Frequency: 50 Hz
22
Tab. 23 Supply Details 200V / 3 / 50Hz
22
Tab. 24 Supply Details 230V / 3 / 50Hz
22
Tab. 25 Supply Details 400V / 3 / 50Hz
22
Mains Frequency: 60 Hz
23
Tab. 26 Network Conditions at 400V / 3 / 50Hz
23
Tab. 27 Supply Details 230V / 3 / 60Hz
23
Tab. 28 Supply Details 380V / 3 / 60Hz
23
Tab. 29 Supply Details 440V / 3 / 60Hz
23
Available Heat Capacity
24
Tab. 30 Supply Details 460V / 3 / 60Hz
24
Tab. 31 Heat Capacity (Option W1)
24
3 Safety and Responsibility Basic Instructions
25
Specified Use
25
Improper Use
25
User's Responsibilities
25
Observe Statutory and Universally Accepted Regulations
25
Determining Personnel
26
Complying with Inspection Schedules and Accident Prevention Regulations
26
Dangers
27
Safely Dealing with Sources of Danger
27
Tab. 32 Inspection Intervals According to Ordinance on Industrial Safety and Health
27
Safe Machine Operation
29
Organisational Measures
31
Danger Areas
31
Safety Devices
32
Working Life of Safety Functions
32
Tab. 33 Danger Areas
32
Tab. 34 Category and Performance Level
32
Safety Signs
33
Fig. 2 Location of Safety Signs
33
Emergency Situations
34
Correct Fire Fighting
34
Treating Injuries from Handling Cooling Oil
34
Tab. 35 Safety Signs
34
Warranty
35
Environment Protection
35
4 Design and Function
36
Enclosure
36
Fig. 3 Enclosure Overview
36
Machine Function
37
Safety Devices
37
Fig. 4 Machine Layout
37
Floating Relay Contacts
38
Operating Panel SIGMA CONTROL
38
Fig. 5 Keys - Overview
38
Fig. 6 Indicators - Overview
39
Tab. 36 Keys
39
Fig. 7 RFID Reader
40
Tab. 37 Leds
40
Operating Modes and Control Modes
41
Machine Operating Modes
41
Tab. 38 RFID Reader
41
Control Modes
42
Tab. 39 Energy-Saving Control Modes
42
Options
43
SIGMA CONTROL 2 Controller: Connection to Control Technology
43
Machine Mountings
43
Fig. 8 Machine Mountings
43
Tab. 40 Components
43
Prepared for External Heat Recovery
44
5 Installation and Operating Conditions
45
Ensuring Safety
45
Installation Conditions
45
Determining Location and Clearances
45
Ensuring the Machine Room Ventilation
46
Fig. 9 Recommended Machine Placement and Dimensions [MM]
46
Exhaust Duct Design
47
Operating the Machine in a Compressed Air Network
47
6 Installation
48
Ensuring Safety
48
Reporting Transport Damage
49
Connecting the Machine with the Compressed Air Network
49
Connecting the External Pressure Transducer
49
Fig. 10 Compressed Air Pipework
49
Connecting the Machine with the Power Supply
50
Options
51
Anchoring the Machine
51
Connecting the External Heat Recovery System
51
7 Initial Start-Up Ensuring Safety
52
Instructions to be Observed before Commissioning
53
Checking Installation and Operating Conditions
53
Tab. 41 Re-Commissioning after Storage/Standstill
53
Setting the Overload Protection Cut-Out
54
Pouring Cooling Oil into the Airend
54
Fig. 11 Charging Hole
54
Tab. 42 Installation Conditions Checklist
54
Activating and Deactivating the MODULATING Control
55
Starting the Machine for the First Time
55
Fig. 12 Activating and Deactivating the MODULATING Control
55
Tab. 43 Activating and Deactivating the MODULATING Control
55
Setting the Set Point Pressure
56
Checking the Door Interlock Switch
56
Setting the Display Language
57
Fig. 13 Position of the Door Interlock Switch
57
8 Operation
58
Switching on and off
58
Switching on
58
Switching off
58
Fig. 14 Switching on and off
58
Switching off in an Emergency and Switching on Again
59
Using the Remote Control for Switching on and off
59
Fig. 15 Switching off in an Emergency
59
Using the Timer for Switching on and off
60
Fig. 16 Using the Remote Control for Switching on and off
60
Tab. 44 Machine Identification
60
Tab. 45 Remote Control Identification
60
Interpreting Operation Messages
61
Acknowledging Alarm and Warning Messages
61
Fig. 17 Using the Timer for Switching on and off
61
Tab. 46 Machine Identification
61
Fig. 18 Acknowledging Messages
62
9 Fault Recognition and Rectification
63
Basic Instructions
63
Other Faults
63
Tab. 47 Other Faults and Remedies
64
10 1 Maintenance
65
Ensuring Safety
65
Tab. 48 Advise Others that the Machine Is Being Serviced
65
Following the Maintenance Plan
66
Logging Maintenance Work
66
Resetting Maintenance Interval Counters
66
Regular Maintenance Tasks
66
Cooling Oil Change Interval
67
Tab. 49 Regular Maintenance Tasks
67
Regular Service Tasks
68
Tab. 50 Cooling Oil Change Intervals
68
Tab. 51 Regular Service Tasks
68
Cooler: Cleaning or Renewing the Filter Mats
69
Control Cabinet: Clean or Renew the Filter Mat
69
Fig. 19 Filter Mat for the Air and Oil Cooler
69
Cooler Maintenance
70
Fig. 20 Switching Cabinet Ventilation
70
Maintaining the External Heat Recovery System
71
Fig. 21 Filter Mat for the Air and Oil Cooler
71
Air Filter Maintenance
72
Compressor Motor Maintenance
72
Fig. 22 Air Filter Maintenance
72
Drive Belt Maintenance
73
Fig. 23 Drive Belt Maintenance
73
Testing the Pressure Relief Valve
74
Check the Safety Shut-Down Due to Excessive Airend Discharge Temperature
75
Check the EMERGENCY STOP Control Device
75
Checking the Cooling Oil Level
75
Fig. 24 Check the EMERGENCY STOP Control Device
75
Tab. 52 Permissible Cooling Oil Level under LOAD
75
Venting the Machine (De-Pressurising)
76
Fig. 25 Checking the Cooling Oil Level
76
Fig. 26 Venting the Machine
77
Replenish Cooling Oil
78
Venting the Machine (De-Pressurising)
78
Fig. 27 Replenish Cooling Oil
78
Topping up with Cooling Oil and Trial Run
79
Changing the Cooling Oil
80
Fig. 28 Changing the Cooling Oil, Oil Separator Tank
81
Fig. 29 Changing the Cooling Oil Oil Cooler
82
Fig. 30 Changing the Cooling Oil, Heat Recovery System
83
Changing the Oil Filter
84
Fig. 31 Changing the Oil Filter
84
Changing the Oil Separator Cartridge
85
Fig. 32 Changing the Oil Separator Cartridge
86
Documenting Maintenance and Service Work
88
Tab. 53 Logged Maintenance Tasks
88
11 Spares, Operating Materials, Service
89
Note the Nameplate
89
Ordering Consumable Parts and Operating Fluids/Materials
89
Kaeser Air Service
89
Tab. 54 Consumable Parts
89
Replacement Parts for Service and Repair
90
12 1 Decommissioning, Storage and Transport
94
Commissioning
94
Temporary De-Commissioning
94
Long-Term De-Commissioning
94
Packing
95
Storage
95
Transport
95
Safety
95
Transport with a Forklift Truck
95
Transport with a Hoist
96
Fig. 33 Transporting with a Forklift Truck
96
Fig. 34 Transporting with a Crane
97
Disposal
98
Dispose of the Battery in Accordance with Local Environmental Regulations
98
Fig. 35 Battery Labelling
98
13 Annex
99
Pipeline and Instrument Flow Diagram (P&I Diagram)
99
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control
105
Dimensional Drawing
111
Electrical Diagram
114
4
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KAESER SK Series Specifications
General
Type
Rotary Screw Compressor
Cooling
Air
Drive
Direct
Control System
SIGMA CONTROL 2
Model
SK Series
Noise Level
66 - 72 dB(A)
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