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KAESER
Air Compressor
SM 15
KAESER SM 15 User Manual
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Operator Manual
Screw Compressor
SM
Tri-Voltage, SIGMA CONTROL 2
9_5875 33 USE
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
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
2 Technical Data Nameplate
14
Options
14
Tab. 3 Nameplate
14
Tab. 4 Options
14
Weight
15
Temperature
15
Ambient Conditions
15
Tab. 5 Machine Weight
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
16
Tab. 9 Safety Relief Valve Activating Pressure
16
Delivery
17
Cooling Oil Recommendation
17
Basic Information
17
KAESER Lubricants
17
Tab. 10 Free Air Delivery
17
Cooling Oil Charge
18
Tab. 11 Cooling Oil Charge (Option K1)
18
Tab. 12 Cooling Oil Charge (Option W1)
18
Motors and Power
19
Compressor Motor
19
Noise Emission
19
Power Supply
19
Tab. 13 Compressor Motor
19
Tab. 14 Compressor Motor: Rated Speed
19
Tab. 15 Noise Emission
19
Power Supply Specifications
20
Fig. 2 Three-Phase Star (Wye System); 4 Wire; Center Point Solidly Grounded
20
Fig. 3 Three-Phase Star (Wye System); 3 Wire; Grounded Center Point Solidly Grounded
20
Tab. 16 Supply Details 208V / 3Ph / 60Hz
20
Tab. 17 Supply Details 230V / 3Ph / 60Hz
20
Available Heat Capacity
21
Tab. 18 Supply Details 460V / 3Ph / 60Hz
21
Tab. 19 Heat Capacity (Option W1)
21
3 Safety and Responsibility Basic Instructions
22
Specified Use
22
Improper Use
22
User's Responsibilities
22
Observe Statutory and Universally Accepted Regulations
22
Qualified Personnel
23
Adherence to Inspection Schedules and Accident Prevention Regulations
23
Dangers
23
Safely Dealing with Sources of Danger
23
Safe Machine Operation
26
Organizational Measures
28
Danger Areas
28
Safety Devices
28
Tab. 20 Danger Areas
28
Working Life of Safety Functions
29
Safety Signs
29
Fig. 4 Location of Safety Signs
29
Emergency Situations
31
Correct Fire Fighting
31
Treating Injuries from Handling Cooling Oil
31
Tab. 21 Safety Signs
31
Warranty
32
Environmental Protection
32
4 Design and Function
33
Enclosure
33
Fig. 5 Enclosure Overview
33
Machine Function
34
Safety Devices
34
Fig. 6 Machine Layout
34
Operating Modes and Control Modes
35
Machine Operating Modes
35
Control Modes
36
Tab. 22 Energy-Saving Control Modes
36
Operating Panel SIGMA CONTROL
37
Fig. 7 Keys - Overview
37
Fig. 8 Indicators - Overview
38
Tab. 23 Keys
38
Fig. 9 RFID Sensor Field
39
Tab. 24 Indicators
39
Tab. 25 RFID Sensor Field
39
Floating Relay Contacts
40
Options
40
Machine Mountings
40
Prepared for External Heat Recovery
40
Fig. 10 Machine Mountings
40
5 Installation and Operating Conditions
42
Ensuring Safety
42
Installation Conditions
42
Determining Location and Clearances
42
Ensuring the Machine Room Ventilation
43
Fig. 11 Recommended Machine Placement and Dimensions [In.]
43
Exhaust Duct Design
44
Operating the Machine in a Compressed Air System
44
6 Installation
45
Ensuring Safety
45
Installation 6.1 Ensuring Safety
45
Reporting Transport Damage
46
Connecting the Machine with the Compressed Air Network
46
Connecting the External Pressure Transducer
46
Fig. 12 Compressed Air Pipework
46
Making the Power Supply Connection
47
Changing Main Voltage Connections
48
Tab. 26 Voltage Selection
48
Tab. 27 Overload Protection Cutout Settings
48
Options
49
Anchoring the Machine
49
Connecting the External Heat Recovery System
49
7 Initial Start-Up Ensuring Safety
50
Instructions to be Observed before Commissioning or Re-Commissioning
51
Checking Installation and Operating Conditions
51
Tab. 28 Re-Commissioning after Storage
51
Setting the Overload Protection Relay
52
Pouring Cooling Oil into the Airend
52
Tab. 29 Installation Conditions Checklist
52
Activating and Deactivating the MODULATING Control
53
Fig. 13 Inlet Valve Filling Port
53
Tab. 30 MODULATING Control: Setting the Shut-Off Valve
53
Starting the Machine for the First Time
54
Fig. 14 MODULATING Control: Setting the Shut-Off Valve
54
Setting the Set Point Pressure
55
Checking the Door Interlock Switch
55
Setting the Display Language
55
Fig. 15 Interlock Switch Position
55
8 Operation
57
Switching on and off
57
Switching on
57
Switching off
57
Fig. 16 Switching on and off
57
Operation 8.1 Switching on and off
57
Switching off in an Emergency and Switching on Again
58
Switching on and off from a Remote Control Center
58
Fig. 17 Switching off in an Emergency
58
Using the Timer for Switching on and off
59
Fig. 18 Switching on and off from a Remote Control Center
59
Tab. 31 Machine Identification
59
Tab. 32 Remote Control Center Identification
59
Interpreting Operation Messages
60
Acknowledging Alarm and Warning Messages
60
Fig. 19 Using the Timer for Switching on and off
60
Tab. 33 Warning Notice for Timer Control
60
Fig. 20 Acknowledging Messages
61
9 Fault Recognition and Rectification
62
Basic Instructions
62
Other Faults
62
Tab. 34 Other Faults and Actions
63
10 Maintenance
64
Ensuring Safety
64
Tab. 35 Warn Others that the Machine Is Being Serviced
64
Following the Maintenance Plan
65
Logging Maintenance Work
65
Resetting Maintenance Interval Counters
65
Regular Maintenance Tasks
65
Cooling Oil Changing Interval
66
Tab. 36 Regular Maintenance Tasks
66
Regular Service Tasks
67
Cooler: Cleaning or Renewing the Filter Mats
67
Tab. 37 Oil Change Intervals Lubricants
67
Tab. 38 Regular Service Tasks
67
Control Cabinet: Clean or Renew the Filter Mat
68
Fig. 21 Filter Mat for the Air and Oil Cooler
68
Cooler Maintenance
69
Fig. 22 Switching Cabinet Ventilation
69
Maintaining the External Heat Recovery System
70
Fig. 23 Filter Mat for the Air and Oil Cooler
70
Air Filter Maintenance
71
Compressor Motor Maintenance
71
Fig. 24 Air Filter Maintenance
71
Drive Belt Maintenance
72
Fig. 25 Drive Belt Maintenance
72
Testing the Safety Relief Valve
73
Checking the Overheating Safety Shutdown Function
74
Testing the EMERGENCY STOP Push Button
74
Checking the Cooling Oil Level
74
Fig. 26 Testing the EMERGENCY STOP Push Button
74
Tab. 39 Permissible Cooling Oil Level under LOAD
74
Venting the Machine (De-Pressurizing)
75
Fig. 27 Checking the Cooling Oil Level
75
Fig. 28 Venting the Machine
76
Replenishing the Cooling Oil
77
Venting the Machine (De-Pressurizing)
77
Fig. 29 Replenishing the Cooling Oil
77
Topping off with Cooling Oil and Trial Run
78
Changing the Cooling Oil
79
Fig. 30 Changing the Cooling Oil, Oil Separator Tank
80
Fig. 31 Changing the Cooling Oil, Heat Recovery System
81
Changing the Oil Filter
82
Changing the Oil Separator Cartridge
83
Fig. 32 Changing the Oil Filter
83
Fig. 33 Changing the Oil Separator Cartridge
84
Documenting Maintenance and Service Work
86
Tab. 40 Logged Maintenance Tasks
86
11 Spares, Operating Materials, Service
87
Note the Nameplate
87
Ordering Consumable Parts and Operating Fluids/Materials
87
Kaeser Air Service
87
Tab. 41 Consumable Parts
87
Service Addresses
88
Spare Parts for Service and Repair
88
12 Decommissioning, Storage and Transport
92
Decommissioning
92
Packing
92
Storage
92
Transport
93
Safety
93
Transport with a Forklift Truck
93
Transport with a Crane
93
Fig. 34 Transport with a Forklift Truck
93
Disposal
94
Fig. 35 Transport with a Crane
94
Battery Disposal
95
Fig. 36 Battery Disposal
95
13 Annex
96
Pipeline and Instrument Flow Diagram (P+I Diagram)
96
Pipe and Instrument Flow Diagram (P+I Diagram): MODULATING Control Mode
102
Dimensional Drawing
108
Electrical Diagram
111
5
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KAESER SM 15 Specifications
General
Model
SM 15
Category
Air Compressor
Motor Power
7.5 kW
Sound Level
66 dB(A)
Voltage
400 V
Frequency
50 Hz
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