Компрессор kaeser руководство по эксплуатации

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  Operating Manual Rotary screw compressor 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…
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  Original instructions /KKW/SSK 2.21 en SBA-SCHRAUBEN-SC2IO /KKW/SSC 2.08 20180629 105600…

• Page 3: Table Of Contents

  Contents Regarding this document Using this document ………………….Further documents ………………….Copyright …………………….. Symbols and labels ………………….1.4.1 Warnings ………………….1.4.2 Potential damage warnings …………….1.4.3 Other alert notes and their symbols …………..Technical Specifications Nameplate ……………………Options ……………………..Mass ……………………..Temperature ……………………

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  Contents Operating panel SIGMA CONTROL 2 …………….Operating modes and control modes …………….4.4.1 Machine operating modes ……………… 4.4.2 Control modes ………………..Options ……………………..4.5.1 SIGMA CONTROL 2 controller: Connection to control technology ….4.5.2 Machine mountings ………………… 4.5.3 Prepared for external heat recovery …………..Installation and Operating Conditions Ensuring safety ……………………
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  10.19 Documenting maintenance and service work …………..Spares, Operating Materials, Service 11.1 Note the nameplate ………………….11.2 Ordering consumable parts and operating fluids/materials ……….11.3 KAESER AIR SERVICE ………………..11.4 Replacement parts for service and repair ……………. Decommissioning, Storage and Transport 12.1 De-commissioning ………………….
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  Contents Operating Manual Rotary screw compressor 901848 21 E…
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  List of Illustrations Fig. 1 Maximum relative humidity of intake air ………………Fig. 2 Location of safety signs ………………….Fig. 3 Enclosure overview ……………………Fig. 4 Machine layout ……………………… Fig. 5 Keys – overview ……………………. Fig. 6 Indicators – overview ……………………Fig.
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  List of Illustrations Operating Manual Rotary screw compressor 901848 21 E…
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  List of Tables Tab. 1 Danger levels and their definition (personal injury) …………..Tab. 2 Danger levels and their definition (damage to property) …………Tab. 3 Nameplate ……………………..Tab. 4 Options ……………………….Tab. 5 Mass ……………………….Tab. 6 Temperature ……………………..Tab.
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  List of Tables Operating Manual Rotary screw compressor viii 901848 21 E…

• Page 11: Regarding This Document Using This Document

  ➤ Make sure you provide the data from the nameplate when ordering documents. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. Symbols and labels ➤…

• Page 12: Potential Damage Warnings

  Regarding this document Symbols and labels Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐ tions. Example: DANGER The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. The word «DANGER»…

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  Regarding this document Symbols and labels Material Here you will find details on special tools, operating materials or spare parts. Precondition Here you will find conditional requirements necessary to carry out the task. The conditions relevant to safety shown here will help you to avoid dangerous situations. Option H1 ➤…

• Page 14: Technical Specifications Nameplate

  Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine’s nameplate. The nameplate is located on the outside of the machine: ■ above the cooler, or ■ on the rear of the machine. ➤…

• Page 15: Mass

  Technical Specifications Mass Mass The values shown are maximum values. Actual mass of individual machines are dependent on equipment fitted. SK 22 SK 25 — Mass [kg] — Tab. 5 Mass Temperature SK 22 SK 25 — Minimum cut-in tempera‐ —…

• Page 16: Ventilation

  Technical Specifications Ventilation Fig. 1 Maximum relative humidity of intake air Intake air temperature [°C] Maximum relative humidity of intake air [%] Ventilation The values given are minimum guide values. Mains frequency: 50 Hz SK 22 SK 25 — Inlet aperture see fig‐…

• Page 17: Flow Rate (Constant Delivery Volume Relative To Intake Conditions)

  Technical Specifications Flow rate (constant delivery volume relative to intake conditions) Pressure relief valve activating pressure at 50 Hz [bar]: Maximum working over‐ SK 22 SK 25 — pressure [bar] — 11.0 — 15.0 —* * China: 15.9 Tab. 10 Pressure relief valve activating pressure (50Hz) Pressure relief valve activating pressure at 60 Hz [bar]: Maximum working over‐…

• Page 18: Cooling Oil Recommendation

  Technical Specifications Cooling oil recommendation Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. For information on ordering cooling oil, please see chapter 11. Cooling oils for general applications SIGMA FLUID S-460 S-570 Description Mineral oil…

• Page 19: Cooling Oil Charge

  Technical Specifications 2.10 Cooling oil charge SIGMA FLUID FG-460 FG-680 Viscosity at 8.0 mm /s (ASTM D445) 10.5 mm /s (ASTM D445) 100 °C Flash point 246 °C (ASTM D92) 238 °C (ASTM D92) Density at 0.842 g/cm (ASTM D1298) 0.854 g/cm (ASTM D1298) 15 °C…

• Page 20: Motors And Power

  Technical Specifications 2.11 Motors and power Option W1 Heat recovery The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines: SK 22 SK 25 — Additional charge vol‐ ume [l]* * Enter the volume required by your heat recovery system. Tab.

• Page 21: Electrical Connection

  Technical Specifications 2.13 Electrical connection Mains frequency SK 22 SK 25 — 60 Hz — Noise pressure level in operation at maximum working gauge pressure as per ISO 2151 and the basic standard ISO 9614-2, uncertainty: ±3 dB(A) Tab. 22 Noise emission [dB(A)] 2.13 Electrical connection…

• Page 22: Mains Frequency: 50 Hz

  Technical Specifications 2.14 Power supply specifications ➤ For other application conditions, check and determine the supply diameters according to DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider. Other conditions would include, for example: ■ Higher ambient temperature ■…

• Page 23: Mains Frequency: 60 Hz

  Technical Specifications 2.14 Power supply specifications The machines listed in the table are intended for operation with a public power supply with a net‐ work impedance at the transfer point (house connection) of maximum Z [Ohm]. max. The operator must ensure that the machines are only connected to a network that meets these re‐ quirements.

• Page 24: Available Heat Capacity

  Technical Specifications 2.15 Available heat capacity Rated voltage: 460V / 3 / 60Hz SK 22 SK 25 — Backup fuse [A] — — Supply cable [mm Current drawn [A] — Tab. 30 Supply details 460V / 3 / 60Hz 2.15 Option W1 Available heat capacity The quality of the heat transfer medium and its required flow rate depend on the type of heat…

• Page 25: Safety And Responsibility Basic Instructions

  Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■…

• Page 26: Determining Personnel

  Safety and Responsibility User’s responsibilities ➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐ nance of the machine. 3.4.2 Determining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.

• Page 27: Dangers

  Inspection Inspection interval Inspecting authority Installation and equip‐ Before commissioning Competent person ment inspection (e. g. KAESER SERVICE technician) Internal inspection Every 5 years after installation or Competent person the last inspection (e. g. KAESER SERVICE technician) Strength test Every 10 years after installation or…

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  Safety and Responsibility Dangers ➤ De-pressurise all pressurised components and enclosures. ➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐ nents (e.g. pipes and vessels) as this influences the component’s resistance to pressure. The safety of the machine is then no longer ensured. Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐…

• Page 29: Safe Machine Operation

  Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts on pressure bearing parts. Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredict‐…

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  Safety and Responsibility Dangers ■ Safety boots ■ Eye protection ■ Ear protection Transport The mass and size of the machine require safety measures during its transport to prevent acci‐ dents. ➤ Use suitable lifting gear that conforms to local safety regulations. ➤…

• Page 31: Organisational Measures

  ➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: for visible damages,…

• Page 32: Safety Devices

  Safety and Responsibility Safety devices Activity Danger area Authorised personnel Transport Within a 3 m radius of the machine. Installation personnel for transport preparation. No personnel during transport. Beneath the lifted machine. No personnel! Installation Within the machine. Installation personnel Within 1 m radius of the machine and its sup‐…

• Page 33: Safety Signs

  Safety and Responsibility Safety signs 1. The components of the safety functions must be replaced by KAESER SERVICE after a work‐ ing life of 20 years. 2. Have the KAESER SERVICE check the reliability of the safety functions. Safety signs The figure shows the position of the safety signs on the machine.

• Page 34: Emergency Situations

  Safety and Responsibility Emergency situations Position Sign Meaning Personal injury or damage to the machine by incorrect operation! ➤ Read and understand the service manual and all safety signs before switch‐ ing on this machine. Risk of injury caused by an automatic machine start! ➤…

• Page 35: Warranty

  ■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11 Environment protection The operation of this machine may cause dangers for the environment.

• Page 36: Design And Function

  Design and Function Enclosure 4 Design and Function Enclosure Fig. 3 Enclosure overview Control cabinet door Sight glass: Oil level indicator Latch Sight glass: V-belt tension Panel (removable) When closed, the enclosure serves various functions: ■ Sound insulation ■ Protection against contact with components ■…

• Page 37: Machine Function

  Design and Function Machine function Machine function Fig. 4 Machine layout Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Compressor motor Air filter Oil filter Oil/air cooler Airend Ambient air is cleaned as it is drawn in through the filter The air is then compressed in the airend The airend is driven by an electric motor Cooling oil is injected into the airend.

• Page 38: Floating Relay Contacts

  Design and Function Operating panel SIGMA CONTROL 2 ■ Pressure relief valve: The pressure relief valve protects the system against excessive pressure. It is factory set. ■ Resistance thermometer: Monitoring the airend discharge temperature protects the compressed air system from imper‐ missible temperature rises.

• Page 39: Fig. 6 Indicators — Overview

  Design and Function Operating panel SIGMA CONTROL 2 Position Name Function «Accept» Jumps to the selected menu option. Exits the edit mode and saves. «Down» Scrolls down the menu options. Reduces a parameter value. «Right» Jumps to the right. Moves the cursor position to the next right field. «Left»…

• Page 40: Fig. 7 Rfid Reader

  Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐ vate the communication between transponder and SIGMA CONTROL 2. A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided with the machine.

• Page 41: Operating Modes And Control Modes

  Design and Function Operating modes and control modes Position Name Function RFID RFID reader for the communication with a suitable RFID transponder. Tab. 38 RFID reader Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐ ing manual.

• Page 42: Control Modes

  Design and Function Operating modes and control modes 4.4.2 Control modes Using the selected control mode, the controller switches the machine between its various opera‐ tional states in order to maintain the gauge working pressure between the set minimum and maxi‐ mum values, regardless of the drawn compressed air volume.

• Page 43: Options

  Design and Function Options VARIO idling The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the time is automatically lengthened or shortened to compensate for higher or lower machine starting frequencies. Option C1 MODULATING control The MODULATING control is an additional mechanical regulation.

• Page 44: Prepared For External Heat Recovery

  Working elements are marked with their opening temperature [°C]. If the cooling oil temperature is too low, condensate can form and damage the machine. ➤ Consult KAESER Service on components and layout to ensure proper functioning of the cooling and heat recovery systems.

• Page 45: Installation And Operating Conditions

  The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be kept to. Precondition The floor must be level, firm and capable of bearing the mass of the machine.

• Page 46: Ensuring The Machine Room Ventilation

  It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine room. 1. Ensure that the flow volume of fresh air is at least the same as the volume taken by the ma‐…

• Page 47: Exhaust Duct Design

  The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐ ing. ➤ Consult the KAESER SERVICE representative before deciding on: ■ Design of the exhaust air ducting ■…

• Page 48: Installation

  Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤…

• Page 49: Reporting Transport Damage

  ➤ Install only corrosion-resistant pipes. ➤ Use fluoroelastomers as sealing material for seals. ➤ Note the electro-chemical voltage sequence. ➤ Consult with KAESER for suitable materials for the compressed air network. Precondition The compressed air system is vented completely to atmospheric pressure.

• Page 50: Connecting The Machine With The Power Supply

  Safety monitoring of the machine’s internal pressure is unaffected. Your authorized KAESER SERVICE technician will be glad to provide support on planning and executing an individual solution. 1. Install the pressure transducer at the selected location in the compressed air network.

• Page 51: Options

  An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within the compressor. Damage to the machine will follow. ➤ Consult KAESER on a suitable heat exchanger and have KAESER SERVICE do the installa‐ tion. Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐…

• Page 52: Initial Start-Up Ensuring Safety

  Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤…

• Page 53: Instructions To Be Observed Before Commissioning

  ➤ Change the cooling oil. ➤ Manually fill the airend with cooling oil. 36 months ➤ Have the overall technical condition checked by an authorised KAESER SERVICE technician. Tab. 41 Re-commissioning after storage/standstill Checking installation and operating conditions ➤ Check and confirm all the items in the checklist before commissioning the machine.

• Page 54: Setting The Overload Protection Cut-Out

  ➤ Check the settings of the overload relay. The overload relay shuts the machine down despite being correctly set? ➤ Contact the authorised KAESER SERVICE. Pouring cooling oil into the airend Before starting the compressor for the very first time and before re-starting after a shutdown period of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend.

• Page 55: Activating And Deactivating The Modulating Control

  Control valve (proportional control) Shut-off valve ➤ Open or close the shut-off valve, depending on the required control mode. The regulating valve is factory set. Consult with KAESER SERVICE before changing. Starting the machine for the first time Precondition No personnel are working on the machine.

• Page 56: Setting The Set Point Pressure

  Initial Start-up Setting the set point pressure 1. Open the user’s shut-off valve to the air network. 2. Switch on the power supply disconnecting device. Control voltage LED is lit continuously. After the controller has carried out a self-test, the green 3.

• Page 57: Setting The Display Language

  The controller displays an alarm message. 2. Close the panel and acknowledge the alarm. The machine does not shut down? ➤ Have the interlock switch checked by an authorised KAESER SERVICE Technician. 7.10 Setting the display language The controller can display text messages in several languages.

• Page 58: Operation

  Operation Switching on and off 8 Operation Switching on and off Always switch the machine on with the «ON» key and off with the «OFF» key. A power supply disconnecting device has been installed by the user. Fig. 14 Switching on and off ON LED «LOAD/IDLE»…

• Page 59: Switching Off In An Emergency And Switching On Again

  Operation Switching off in an emergency and switching on again Voltage applied to controller LED extinguishes. The machine is switched off and disconnected Result from the mains supply. In rare cases, you may want to shut down the machine immediately and cannot wait until the automatic shut-down process is finished.

• Page 60: Using The Timer For Switching On And Off

  Operation Using the timer for switching on and off Fig. 16 Using the remote control for switching on and off «Remote control» key Remote control LED 1. Attach an easily seen notice to the machine that warns of remote operation. Remote control: Risk of injury caused by unexpected starting! ➤…

• Page 61: Interpreting Operation Messages

  Operation Interpreting operation messages Fig. 17 Using the timer for switching on and off «Timer» key Timer LED 1. Attach an easily seen notice warning of time-controlled operation: Time control: Risk of injury caused by unexpected starting! ➤ Make sure that the power supply disconnecting device is switched off before commencing any work on the machine.

• Page 62: Fig. 18 Acknowledging Messages

  Operation Acknowledging alarm and warning messages Fig. 18 Acknowledging messages Warning LED (yellow) Fault LED (red) «Acknowledge» key Alarm message Fault LED flashes red. An alarm shuts the machine down automatically. The The system displays the appropriate message. Precondition The fault has been rectified ➤…

• Page 63: Fault Recognition And Rectification

  1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorised KAESER SERVICE representative. Further information See the operating manual of SIGMA CONTROL 2 for details regarding the various messages.

• Page 64: Tab. 47 Other Faults And Remedies

  Oil cooler leaking. Call KAESER SERVICE. Leaking pipe joints. Tighten pipe joints. Replace seals. Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐…

• Page 65: 10.1 Maintenance

  Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤…

• Page 66: Following The Maintenance Plan

  Details of dangers and their avoidance are found in chapter 3.5. 10.2 Following the maintenance plan 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■…

• Page 67: Cooling Oil Change Interval

  Maintenance 10.2 Following the maintenance plan ➤ Take note of the controller’s service messages and carry out tasks punctually, taking ambient and operating conditions into account. Interval Maintenance task see chapter Weekly Check the cooling oil level. 10.13 Cooler: 10.3 Check the filter mat Control cabinet: 10.4…

• Page 68: Regular Service Tasks

  Maintenance 10.2 Following the maintenance plan KAESER SERVICE will support you in determining appropriate intervals and provide informa‐ tion on the possibilities of oil analysis. ➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐…

• Page 69: Cooler: Cleaning Or Renewing The Filter Mats

  Maintenance 10.3 Cooler: Cleaning or Renewing the Filter Mats 10.3 Cooler: Cleaning or Renewing the Filter Mats The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the components is no longer ensured. Material Filter mats: Warm water and household detergent…

• Page 70: Cooler Maintenance

  Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions clog the cooling air ducts in the machine’s interior and the motors resulting in increased wear and tear. ➤ Have the authorised KAESER SERVICE technician clean the cooling air ducts. Material Brush and vacuum cleaner…

• Page 71: Maintaining The External Heat Recovery System

  ➤ Have stubborn clogging removed by an authorized KAESER SERVICE technician. Checking the cooler for leaks ➤ Carry out visual inspection: Did cooling oil escape? Is a cooler leaking? ➤ Have the defective cooler repaired immediately by a KAESER SERVICE technician. 10.6 Option W1 Maintaining the external heat recovery system Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.

• Page 72: Air Filter Maintenance

  Compressor motor maintenance The anti-friction bearings of the compressor motor are permanently greased. Re-greasing is not necessary. ➤ Have the anti-friction bearings checked by an authorised KAESER SERVICE technician in the course of a maintenance visit. Operating Manual Rotary screw compressor…

• Page 73: Drive Belt Maintenance

  Maintenance 10.9 Drive belt maintenance 10.9 Drive belt maintenance Material Spare parts (if required) Precondition The power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified. The machine has cooled down. WARNING Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐…

• Page 74: Testing The Pressure Relief Valve

  Maintenance 10.10 Testing the pressure relief valve Changing the belt 1. Loosen the locking nut 2. Turn adjusting nut to loosen the tension on the belt until it can be removed from the pulley. 3. Install the new belt and use the adjusting nut to adjust tension until the marker pin reaches the lower end of the elongated hole.

• Page 75: Check The Safety Shut-Down Due To Excessive Airend Discharge Temperature

  ➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐ ual. The machine does not shut down? ➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐ nician. 10.12 Check the EMERGENCY STOP control device Fig.

• Page 76: Venting The Machine (De-Pressurising)

  Maintenance 10.14 Venting the machine (de-pressurising) In frequency-controlled compressors (SFC) the oil level indicator sis only accurate when the machine is running at or near maximum speed. The lower the pressure at the compressed air outlet, the higher the speed. Precondition The machine has been running at least 5 minutes under LOAD.

• Page 77: Fig. 26 Venting The Machine

  ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐…

• Page 78: Replenish Cooling Oil

  Maintenance 10.15 Replenish cooling oil 2. Slowly open the shut-off valve to release pressure. 3. Disconnect the male hose fitting and close the shut-off valve 10.15 Replenish cooling oil The machine must be isolated from the compressed air network and completely vented be‐ fore undertaking any work on the pressure system.

• Page 79: Topping Up With Cooling Oil And Trial Run

  ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐…

• Page 80: Changing The Cooling Oil

  Maintenance 10.16 Changing the cooling oil 4. Top up to bring the oil to the correct level. 5. Renew the filler plug’s gasket if necessary and screw the plug into the filler port. Starting the machine and performing a trial run 1.

• Page 81: Fig. 28 Changing The Cooling Oil, Oil Separator Tank

  Maintenance 10.16 Changing the cooling oil Fig. 28 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Shut-off valve open Pressure gauge Shut-off valve closed Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drainage) Cooling oil level indicator.

• Page 82: Fig. 29 Changing The Cooling Oil Oil Cooler

  Maintenance 10.16 Changing the cooling oil Draining the oil from the separator tank Contact KAESER SERVICE if condensate is detected in the cooling oil. It is necessary to adapt the airend discharge temperature to individual ambient conditions. Precondition Cut-off the electrical power supply via the power supply isolating device, ensure that the device is locked off, verify the absence of any voltage.

• Page 83: Fig. 30 Changing The Cooling Oil, Heat Recovery System

  Maintenance 10.16 Changing the cooling oil Option W1 Draining the oil from the thermostatic valve A drain plug is provided to drain oil from the thermostatic valve. If the machine is connected to an external heat recovery system, oil should also be drained from the heat exchanger at a suitable point.

• Page 84: Changing The Oil Filter

  Maintenance 10.17 Changing the oil filter 10.17 Changing the oil filter The machine must be isolated from the compressed air network and completely vented be‐ fore undertaking any work on the pressure system. Material Spares Cooling oil receptacle Precondition The power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified.

• Page 85: Changing The Oil Separator Cartridge

  Maintenance 10.18 Changing the oil separator cartridge Starting the machine and carrying out a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user’s shut-off valve between the machine and the air distribution network. 3.

• Page 86: Fig. 32 Changing The Oil Separator Cartridge

  Maintenance 10.18 Changing the oil separator cartridge Fig. 32 Changing the oil separator cartridge Cover Screw connection Dirt trap seal Air pipe Oil separator cartridge Retaining screw Ball (functioning as a check valve) Self-locking nut Strainer Changing the oil separator cartridge 1.

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  Maintenance 10.18 Changing the oil separator cartridge Start the machine and carry out a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user’s shut-off valve between the machine and the air distribution network. 3.

• Page 88: Documenting Maintenance And Service Work

  Maintenance 10.19 Documenting maintenance and service work 10.19 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 53 Logged maintenance tasks Operating Manual Rotary screw compressor 901848 21 E…

• Page 89: 11 Spares, Operating Materials, Service

  ➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original components. They are specifically selected for use in KAESER machines. Unsuitable or poor quality consumable parts and operating fluids/materials may result in damage to the machine or impair its proper function.

• Page 90: Replacement Parts For Service And Repair

  Spares, Operating Materials, Service 11.4 Replacement parts for service and repair ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed air availability. 11.4 Replacement parts for service and repair Use this spare parts list to plan your material requirement according to operating conditions and to order the required spare parts.

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  Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E…
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  Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E…
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  Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E…

• Page 94: 12.1 Decommissioning, Storage And Transport

  Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: ■ The machine is (temporarily) not needed. ■ The machine is to be moved to another location. ■ The machine is to be scrapped.

• Page 95: Packing

  Mass and centre of gravity determine the most suitable method of transportation. The centre of gravity is shown in the drawing in chapter 13.3. ➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐ tures.

• Page 96: Transport With A Hoist

  Attached components such as centrifugal separators, condensate drains or filters ■ Rain protection covers ➤ Consult KAESER if you require suitable load-carrying and attachment devices or have questions regarding the correct use. Precondition Load-carrying and attachment devices meet the local safety regulations.

• Page 97: Fig. 34 Transporting With A Crane

  Decommissioning, Storage and Transport 12.4 Transport Fig. 34 Transporting with a crane Load carrying devices Attachment resources Crossbeam 1. WARNING! Risk of accident caused by incorrect use of load-carrying and attachment devices! ➤ Comply with permissible load limits. ➤ Comply with specific safety information of used load-carrying and attachment devices. 2.

• Page 98: Disposal

  Decommissioning, Storage and Transport 12.5 Disposal 12.5 Disposal When disposing of a machine, drain out all liquids and remove old filters. Precondition The machine is decommissioned. 1. Completely drain the cooling oil from the machine. 2. Remove used filters and the oil separator cartridge. 3.

• Page 99: 13 Annex

  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…

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  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E…

• Page 105: Pipeline And Instrument Flow Diagram (P&I Diagram) Modulating Control

  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control 13.2 Option C1 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…

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  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…
• Page 110
  Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E…

• Page 111: Dimensional Drawing

  Annex 13.3 Dimensional drawing 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E…

• Page 112
  Annex 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E…
• Page 113
  Annex 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E…

• Page 114: Electrical Diagram

  Annex 13.4 Electrical Diagram 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…

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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
• Page 119
  7.3217.0 / QRUV 7.3217.0 / QRUV Switching element Schlegel Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO Control cabinet KAESER KAESER 7.7681.0 7.7681.0 7.7681.0 7.7681.0 7.7681.0 Mounting plate KAESER KAESER 212761.0 212761.0 212761.0…
• Page 120
  7.3217.0 / QRUV 7.3217.0 / QRUV Switching element Schlegel Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO Control cabinet KAESER KAESER 7.7681.0 7.7681.0 7.7681.0 7.7681.0 7.7681.0 Mounting plate KAESER KAESER 212761.0 212761.0 212761.0…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…
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  Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E…

• Page 1
  Operator Manual Screw Compressor M100 No.: 9_6999 23 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…
• Page 2
  Original instructions /KKW/M100 2.03 en Z1 SBA-MOBILAIR 20150112 161243…

• Page 3: Table Of Contents

  Fuel recommendation ………………2.6.4 Recommended Cooling Fluid …………….2.6.5 Fluid volumes …………………. 2.6.6 Battery …………………… Options ……………………..2.7.1 Air treatment options ………………. 2.7.2 Low temperature equipment …………….2.7.3 Generator (50 Hz version) ……………… Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 4
  Options for operating in fire hazard areas …………4.7.5 Generator option ………………..4.7.6 Transport options ………………..4.7.7 Sealed floor pan option ………………4.7.8 Optional anti-theft device ………………. 4.7.9 Pedestrian protection option …………….4.7.10 Instrument panel cover option …………….Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 5
  9.2.2 Engine does not reach full speed …………… 9.2.3 Indicator lamp remains on ……………… Compressor faults and alarms ………………9.3.1 Working pressure too high ……………… 9.3.2 Working pressure too low………………. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 6
  10.8.7 Engine air intake shut-off valve maintenance …………. 168 10.8.8 Generator drive belt maintenance …………..169 10.8.9 Draining liquid accumulation within the machine ……….172 10.9 Documenting maintenance and service work …………..Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 7
  Spares, Operating Materials, Service 11.1 Note the nameplate ………………….175 11.2 Ordering consumable parts and operating fluids/materials ……….175 11.3 KAESER AIR SERVICE ………………..176 11.4 Service Addresses ………………….176 11.5 Replacement parts for service and repair ……………. 176 Decommissioning, Storage and Transport 12.1 De-commissioning ………………….
• Page 8
  Contents Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 9
  Fuel filter with water trap maintenance ………………116 Fig. 52 Changing the fuel pre-filter………………….117 Fig. 53 Fuel micro-filter maintenance ………………… 117 Fig. 54 Checking the engine oil level …………………. 119 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 10
  Safety sign — secure the chocks ………………..Fig. 106 Transporting using a forklift truck ………………..242 Fig. 107 Guys to secure the freight ………………….243 Fig. 108 Identification ……………………..245 Operator Manual Screw Compressor viii M100 No.: 9_6999 23 USE…
• Page 11
  Compressed air delivery with generator in operation (generator with FAD limitation) ….Tab. 50 Connection sockets ……………………Tab. 51 Circuit breaker ……………………..Tab. 52 Generator operating limits ………………….Tab. 53 Maximum three-phase mains loading ………………Tab. 54 Maximum single-phase mains loading ………………Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 12
  Maintenance intervals and regular maintenance tasks ………….. 101 Tab. 87 Regular machine maintenance tasks ………………102 Tab. 88 Regular maintenance task options ………………… 104 Tab. 89 KAESER coolant mixture table ………………..108 Tab. 90 Maintenance log ……………………. 174 Tab. 91 Compressor consumables ………………….175 Tab. 92 Consumable engine parts ………………….

• Page 13: Regarding This Document Using This Document

  Copyright This operator manual is copyright protected. Queries regarding use or duplication of the documen‐ tation should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document.

• Page 14: Potential Damage Warnings

  The conditions relevant to safety shown here will help you to avoid dangerous situations. ➤ This symbol is placed by lists of actions comprising one stage of a task. 1. For instructions with several steps … 2..the sequence of actions is numbered. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 15
  The cause is named in the help text … ➤ … and a remedy given. This symbol refers to important information or measures concerning environmental protec‐ tion. Further information Further topics are introduced here. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 16: Technical Data Nameplate

  ■ On the front of the machine (see chapter 13.1) The following table lists all possible options. Only the codes for those options fitted on the machine appear on the nameplate. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 17: Compressed Air Treatment Devices

  Technical Data Options M100 Part Number Serial no. Options fitted hc hd ca cb bb bc bd ga gb r1= rb; rc; rd r3= rm; ro r4= rr; rs; rt r5= rw; rx pa pb 02-M0277 *r1 — r5 = place holders for chassis options Tab.

• Page 18: Check Valve Function

  Option la, lb Equipment for fire hazard areas Option Option code Available? Spark arrestor Spark arrestor and engine air intake shut-off valve (automatic) Tab. 11 Optional equipment for fire hazard areas Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 19: Battery Isolating Switch

  Without height adjustment Service brake (rs): With overrun brake Tab. 13 Chassis options Stationary frame Chassis Option code Available? Stationary (rw, rx): on skids on frame Tab. 14 Options, stationary frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 20: Lighting

  Option sf Anti-theft device Option Option code Available? Anti-theft device Tab. 18 Anti-theft device option 2.2.14 Option sg Pedestrian protection Option Option code Available? Pedestrian protection Tab. 19 Pedestrian protection option Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 21: Instrument Panel Cover

  Instrument panel cover options Machine (without options) 2.3.1 Sound pressure level Sound pressure levels comply with the American EPA Standard. Measurement distance: 23 ft M100 Guaranteed sound pressure level [dB(A)] Tab. 21 Sound pressure level 2.3.2 Tightening torques for screws Recommended values for screws of property class 8.8…

• Page 22: Chassis

  [%] Cross-section width Radial design Use the following table for detailed information regarding the tires of your machine: Characteristic/marking Value Axle load high Tire size 185 R 14C 195 R 14C Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 23: Wheel Nut/Bolt Tightening Torque

  FAD as per ISO 1217:2009. Annex D Tab. 28 Working pressure and FAD 2.5.2 Compressed air outlet Outlet valve [«] Number G 3/4 G 1 1/2 Tab. 29 Compressed air distributor Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 24: Safety Relief Valves

  Airend discharge temperature 2.5.5 Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 25: Tab. 33 Cooling Oil Recommendations

  Viscosity at 50.7 mm 70.0 mm 104 °F (D 445; ASTM test) (D 445; ASTM test) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 26: Cooling Oil Charge

  Oil consumption relative to fuel consumption [%] approx. 0.5 Tab. 36 Engine specification 2.6.2 Oil recommendation The engine oil must meet the following classification: ■ ACEA, class E4, E7 ■ API, class CF, CI-4 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 27: Fuel Recommendation

  The engine service manual gives further information on coolant application. 2.6.5 Fluid volumes Description Fluid volume [gal] Engine oil Fuel 39.63 Coolant 4.23 Tab. 38 Fluid volumes 2.6.6 Battery Feature Value Voltage [V] Capacity [Ah] Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 28: Options

  ■ Cyclone separator ■ Filter combination da + dd + db ■ After-cooler technically oil-free and warmed ■ Cyclone separator ■ Filter combination ■ Heat exchanger Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 29: Low Temperature Equipment

  Antifreeze protection for air brake systems 0.32 (e.g., Wabcothyl) Tab. 45 Recommended antifreeze 2.7.2.4 Option bd Battery Feature Value Voltage [V] Capacity [Ah] PTC testing current [A] (according to EN 50342) Tab. 46 Battery, low-temperature equipment Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 30: Generator (50 Hz Version)

  13.0 [kVA] 8.5 [kVA] Maximum working pres‐ sure [psi] FAD [cfm] − generator FAD cfm] − generator ON Tab. 48 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 31: Tab. 49 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)

  Tab. 51 Circuit breaker Operating limits: (to EN 60034-22, page 10, table) Features Value Design category Voltage adjustment range [%] ±5 Static voltage deviation [%] Maximum dynamic voltage drop [%] –15 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 32: Tab. 52 Generator Operating Limits

  Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 55 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 33: Generator (60 Hz Version)

  Generator 8.0 [kVA] Maximum working pres‐ sure [psig] Free air delivery [cfm] FAD with simultaneous generator operation [cfm] Tab. 57 Compressed air delivery with generator in operation (generator without FAD limitation) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 34: Tab. 58 Compressed Air Delivery With Generator In Operation (Generator With Fad Limitation)

  Maximum voltage settling time [ms] 1500 Maximum voltage asymmetry [%] Tab. 61 Generator operating limits Maximum power loading by consumers Resistive consumers include lamps and heaters, for example. Electric motors and transformers are inductive consumers. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 35: Tab. 62 Maximum Power Supply Load

  Power reduction at elevated ambient temperatures: Ambient temperature Generator power [°F] ≤86 Full power available >86 Reduction of 10 % for each temperature rise of 50 °F. Tab. 63 Power reduction at elevated ambient temperatures Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 36: Safety And Responsibility Basic Instructions

  ➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in effect. User’s Responsibilities 3.4.1 Observe statutory and universally accepted regulations ➤ Observe relevant statutory and accepted regulations during operation, transporting and main‐ tenance of the machine. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 37: Determining Personnel

  This regulation requires that machines filled with more than 0.26 gallons petrol or 1.32 gallons die‐ sel (in the fuel tank) during transport must be identified with hazardous goods labels on the ma‐ chine’s exterior. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 38: Dangers

  ➤ Do not allow fuel to overflow. ➤ Wipe up spilled fuel immediately. ➤ Provide a fire extinguisher in the immediate vicinity. ➤ For operation in combustible environment, fit the machine with an exhaust silencer (Option la). Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 39
  Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. Minimum pressure / check valves, safety relief valves, and inlet valves are powerfully spring-loa‐ ded. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 40
  ➤ Do not eat or drink while handling fuel, cooling and lubricating fluids or antifreeze. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine.

• Page 41: Safe Machine Operation

  Dangers ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER pressure components. Conversion or modification of the machine Modifications, additions or conversions to or of the machine can result in unpredictable hazards.

• Page 42
  ➤ Do not position the machine directly against a wall. A build up of heat from the exhaust can damage the machine. ➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐ drance. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 43
  ➤ De-pressurise all pressurised components and enclosures. ■ Wait until the machine has automatically vented. ■ Carefully open the compressed air outlet valve. ■ Check: The pressure gauge must read 0 psig! Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 44: Organizational Measures

  ➤ Do not open the body while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Operate the machine only in technically sound condition.

• Page 45: Danger Areas

  More information on safety devices is contained in chapter 4.5. Safety signs The diagram shows the positions of safety signs on the machine. The table lists the various safety signs used and their meanings. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 46: Fig. 2 Location Of Safety Signs

  ➤ Always wipe up fuel spills which may occur inside the compressor enclo‐ sure and allow the machine to ventilate. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 47
  ➤ Food grade coolant must be used for food processing. * Location within the machine ** Only towable machines *** Only machines with option dc **** only machines with option ga, gb Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 48: Tab. 65 Safety Signs

  Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded. ➤ Never open (dismantle) valve. ➤ Contact an authorized KAESER service representative. 830**** There is danger of fatal injury touching electrically live components! ➤…

• Page 49: Noise Control Requirements

  ➤ Only a qualified electrician is allowed to carry out work on the generator or generator control box. The electrician is responsible for the effectiveness of the protective measures provided. ➤ Do not use the generator for feeding the construction current distribution. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 50: Connecting Extension Cables

  ➤ Check and tighten the screw connections at the generator and the generator control cubicle. ➤ Check covers and power socket caps for damage and good sealing. ➤ Check the completeness of labeling and warning labels. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 51: Emergencies

  Skin contact Fuel, oil and other fluids/materials may irritate after prolonged contact. ➤ Wash thoroughly with skin cleaner, then with soap and water. ➤ Contaminated clothing should be intensively cleaned before reuse. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 52: Warranty

  ■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11.1 Noise emissions warranty The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built, and equipped to conform, at the time of sale to the first retail pur‐…

• Page 53: Environmental Protection

  ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐ mental protection regulations. ➤ Observe relevant regulations. This applies particularly to parts contaminated with fuel, oil, coolants and acids. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 54: Design And Function Bodywork

  Safe and reliable operation is only ensured when the bodywork is closed. The wing doors are provided with handles for opening. Release the doors by the snap fasteners. The doors are held open by gas springs. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 55: Component Identification

  Pressure relief valve Tool box Lifting eye cover Airend Lifting eye Inlet valve Machine function Machine function (without options) Item numbers correspond to the pipe and instrument flow diagram (P&ID) in chapter 13.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 56: Fig. 6 Machine Layout

  . The minimum pressure / check valve ensures that there is always a minimum internal pressure sufficient to maintain cooling oil circulation in the ma‐ chine. The cooling fan ensures optimum cooling of all components within the enclosure. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 57: Operating Modes And Control Mode

  This stepless delivery regulation minimises fuel consumption of the engine. The load and fuel con‐ sumption of the engine rises and falls with the air demand. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 58: Safety Devices

  Safety devices 4.5.1 Monitoring functions with shutdown The following functions are monitored automatically. ■ Engine oil pressure ■ Coolant temperature ■ Airend discharge temperature ■ Fuel level ■ Engine alternator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 59: Further Safety Devices

  (red) to indicate an alarm. The alarm is saved and the engine cannot be restarted. You can restart the machine only after deactivating and refilling the machine. Options The options available for your machine are described below. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 60: Compressed Air Treatment Options

  The oil/air heat exchanger is fed with hot compressor cooling oil that warms the outgoing moisture- reduced compressed air. This warm, dry compressed air is ideal for sand blasting, for example. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 61
  The oil flow can be stopped by a shut-off valve. The oil flow adjusts automatically to changes in air demand (one or more tools/consumers on line). Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 62: Fig. 10 Tool Lubricator

  Fig. 11 Principle tool lubricator Compressed air inlet Tool lubricator upper part with oil filling port Oil tank Filler plug with dipstick and integrated riser Tool oil outlet tube Metering knob Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 63: Low Temperature Equipment Options

  Option bc Frost protection Control air is mixed with an alcohol-based antifreeze to prevent control and regulating devices freezing. This considerably lowers the freezing point of any moisture in the air. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 64: Optional Battery Isolating Switch

  Damage to the machine’s electrical components is possible. ➤ Use the «battery isolating switch» only when the machine is shut down. ➤ Do not use the «battery isolating switch» as a main or emergency switch. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 65: Options For Operating In Fire Hazard Areas

  A spark arrestor on the exhaust silencer is required when operating a diesel engine in a fire hazard area and in forestry and agricultural applications. In such applications, a spark may ignite flamma‐ ble materials. The spark arrestor prevents the exhaust silencer emitting any glowing fuel residue. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 66: Generator Option

  Engine run-on time of approximately 2 mi‐ nutes at maximum speed Advantages Fuel saving Continuous generator power Constant oscillation between maximum and available without delay minimum speed avoided Tab. 67 Generator operating modes Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 67: Fig. 15 Instrument Panel — Generator Control Box, 400 V Ac

  Instrument panel – generator control box, 230 V AC «Mode selector switch» Generator control box 32 A three-phase power socket «Generator main switch» Single-phase power sockets «Safety cut-out» 16 A three-phase power socket «Safety cut-out» (with overcurrent release) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 68: Transport Options

  Option rb/rk/rm/rs Chassis Option rb — chassis EU version Option rk — Chassis with low axle load Option rm — chassis with height-adjustable tow bar Option rs — chassis with overrun brake Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 69
  Option rb/rl/rm/rs Chassis Option rb — chassis EU version Option rl — Chassis with higher axle load Option rm — chassis with height-adjustable tow bar Option rs — chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 70: Sealed Floor Pan Option

  When other components are removed from the sealed floor pan, (for example the sheet metal cover) they must be properly re-sealed prior to installation. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 71: Optional Anti-Theft Device

  The machine is fitted with a security chain as theft protection. 4.7.9 Option sg Pedestrian protection option The machine is fitted with a special protective guard that prevents pedestrians from being run over. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 72: Instrument Panel Cover Option

  To prevent unauthorized use and as protection during transport the machine is fitted with instru‐ ment panel cover(s). ■ Instrument panel cover (option pa) ■ Generator control box cover (option ga) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 73: Installation And Operating Conditions

  Installation conditions Precondition The floor must be level, firm and capable of bearing the weight of the machine. Fig. 21 Minimum distance from excavations/slopes and walls Wind direction Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 74
  ➤ Use winter grade engine oil. ➤ Use winter diesel fuel. ➤ Use low viscosity compressor cooling oil. 10. At ambient temperatures below 32 °F, follow the instructions in chapter 7.4. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 75: Installation

  Precondition The machine is standing firm and level. The machine is switched off. Danger of pinching! Severe pinching injury to fingers is possible. ➤ Always wear protective gloves. ➤ Work carefully. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 76: Fitting The Height Adjustable Towbar

  Manually tighten the locking lever. ■ Use a hammer to hit the locking lever to further tighten the lower serrated joint until the bore and the groove for the splint pin are aligned Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 77: Fitting A Non-Adjustable Tow Bar

  2. Remove the bag with the brake transfer cable and fastenings, unpack and lay out ready. 3. Close the doors. 4. Remove all transport securing items (screw fastenings, duct tape, foam pads) from the tow bar components. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 78: Fig. 25 Fitting The Overrun Braking Mechanism Of The Non-Adjustable Tow Bar

  6. Screw the the brake-rod linkage onto the rear screw fastening of the brake transfer cable and secure with a lock nut. Further information Further information on setting the brake actuating rod is to be found in chapter 10.7.3.3. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 79: Adjusting The Chassis

  The machine is disconnected from the towing vehicle and safely parked. Danger of pinching! Severe injury to fingers is possible if they become trapped in the adjusting mechanism. ➤ Always wear protective gloves. ➤ Work carefully. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 80: Adjusting The Towbar Height

  The serrated joint will not disengage. The serrations are corroded together. ➤ Free the serrations by jerking the towbar horizontally and vertically. 6.4.2 Changing the towing eye/ball hitch The towbar can be fitted with various towing eyes or couplings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 81: Fig. 28 Changing The Towing Eye (Height-Adjustable Drawbar)

  2. Unscrew the nuts of both screw connec‐ 2. Remove the coupling from the towbar tions and withdraw the bolts 3. Remove the towing eye from the tow‐ Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 82: Fig. 29 Changing The Towing Eye/Ball Hitch (Fixed Height Towbar)

  Fig. 29 Changing the towing eye/ball hitch (fixed height towbar) Self-locking hexagon nut Towbar Hex-head screw Shock absorber Shock absorber fixing eye Mounting pin Hex-head screw Ball coupling Protective sleeve Towing eye Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 83: Fig. 30 Changing The Towing Eye (Fixed Height Towbar, Usa Chassis Version)

  10. Draw the protective sleeve over the fixings. Checking the overrun braking mechanism ➤ Push the towbar tube in and out by hand. If resistance is felt, the shock absorber is properly connected. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 84: Initial Start-Up Ensuring Safety

  ➤ Remove all packing materials on and in the machine. ➤ Observe the machine during the first few hours of operation to ensure that it is operating cor‐ rectly. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 85: Special Measures For Re-Commissioning After Storage

  ➤ Clean the bodywork with a grease and dirt dissolving agent. ➤ Check the tire pressures. 36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐ ice Technician. Tab. 68 Measures for re-commissioning the compressor after a long period of storage Checking installation and operating conditions ➤…

• Page 86: Low-Temperature Operation (Winter)

  ➤ Observe the instructions provided with the battery jumper cables. ➤ Do not connect the battery jumper cables to the negative pole of the discharged battery or to the bodywork of the machine. ➤ Work with caution. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 87: Fig. 31 Jumper Cable Connection Diagram

  1. Park the assisting vehicle in close distance to the engine, without their bodywork touching each other. 2. Stop the engine of the assisting vehicle. 3. Open the accesses to the batteries (remove maintenance panels/bonnet and pole caps). 4. Switch off all power consumers. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 88: Starting Up Low-Temperature Equipment

  Operating the engine cooling water pre-heater The engine coolant can be pre-heated to improve starting under cold conditions. The connection for the power supply is located on the machine’s instrument panel. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 89: Fig. 32 Engine Coolant Pre-Heating

  Frost protector Ball valve (closed) Level of antifreeze ➤ Use the checklist when initially starting the frost protector. To be checked see chapter Confirmed? Level of antifreeze in the frost protector. 10.8.5 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 90: Activating The Generator

  «Mode selection switch» («Circuit breaker» designed as automatic Test button «Insulation monitor» with indi‐ circuit-breaker with shunt trip) ground short cator light for Three-phase AC power sockets Single-phase AC power sockets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 91: Fig. 36 Insulation Monitoring — 115 V, Single-Phase Generator

  1. Activate the machine. Danger of fatal injury caused by contact with live components! ➤ The generator may only be used if the «circuit breaker» («main circuit breaker») has trip‐ ped during the test! Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 92: Tab. 71 Test Instructions For A Generator With An Ground Short Detection Device

  The «main circuit breaker» trips. Problem: The «main circuit breaker» does not trip out? ➤ Shut down the generator and call your authorized KAESER service representative. Tab. 71 Test instructions for a generator with an ground short detection device. Operator Manual…

• Page 93: Operation

  The hose length represents a cooling section. With increasing cooling, the compressed air gives off moisture capable of damaging the air tool. ➤ Use short compressed air hoses. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 94: Starting And Stopping

  Fuel level monitoring light – On – – Preheat – START LOAD – «Load On» key with integrated mode indicating light Back-pressure indicating light – Charging indicating light, group alarm lamp Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 95: Starting The Machine

  To avoid unnecessary wear, the engine should be run in IDLE until the airend discharge tempera‐ ture reaches +86 °F. The airend discharge temperature is shown at the remote thermometer con‐ tact on the instrument panel. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 96: Switching To Load

  The required pressure can be seen on the gauge on the instrument panel. The pressure setting on the proportional controller can only be lower than the maximum working pressure of the machine. Precondition The machine is switched off. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 97: Shutting Down The Machine

  The engine runs in IDLE and the turbo charger can cool down. 3. After approx. 2 to 3 minutes, switch the «starter switch» to the «STOP/Off» position. The engine turns off. Shutting down the machine: 1. Open the right-hand access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 98: Monitoring Fuel Level In The Fuel Tank

  The machine is switched off. Tool lubricator is filled with oil Fig. 41 Setting the tool lubricator Shut-off valve I – open 0 – closed Metering knob ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 99: Using The Low-Temperature Equipment

  Using the low-temperature equipment ➤ Ascertain which low temperature equipment is fitted to the machine. 8.5.1 Option bb Pre-warms the engine cooling water ➤ Start the engine coolant pre-heating as described in chapter 7.4.2. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 100: Operating The Machine With Frost Protector

  See chapter 10.8.5 for filling the frost protector with antifreeze. Using with the frost protector switched off Operating at temperatures above 32 °F (summer operation). 1. Leave the frost protector shut-off valve open permanently (position I). 2. Close the door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 101: Operating The Battery Isolating Switch

  ➤ Check correct function of the insulation monitoring device daily (see chapter 7.5). ➤ Have the generator and control box checked annually by a qualified electrician (see chapter 13.9). ➤ Follow instructions in chapter 3.9. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 102: Note When Operating The Generator

  ■ Switch off electrical consumers and unplug them one-by-one. ■ Switch off consumers drawing the highest current last. ■ Check that the protective covers on the power sockets are correctly closed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 103: Cleaning The Machine After Operation

  Water has accumulated in the sealed floor pan. ➤ Drain the water. Catch the liquid and dispose in accordance with applicable environmental regulations. Further information See chapter 10.8.9 for information to the draining of liquids within the machine. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 104: Fault Recognition And Rectification

  1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Observe the instructions in chapter 3 «Safety and Responsibility» and prevailing local safety regula‐…

• Page 105: Engine Does Not Reach Full Speed

  Tighten the connection or have – bles loose or broken the cable replaced. Defective alternator. Have repaired or replaced if – necessary. Defective alternator regulator. Have repaired or replaced if – necessary. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 106: Compressor Faults And Alarms

  Pressure relief valve maladjus‐ Have repaired or replaced if – ted and/or leaking. necessary. Venting valve does not close. Check the connections and – function and have repaired or replaced as necessary. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 107: Pressure Relief Valve Blowing Off

  1 psi. See chap‐ ter 10.4.6 for changing. Compressor oil filter clogged. Change, see chapter 10.4.4. – – Compressor cooling oil level too Topping up, see chapter 10.4.2. – – low. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 108: Too Much Oil Residue In The Compressed Air

  Specialized KAESER workshop Service Defective non-return function of Repair or have replaced if nec‐ – the inlet valve. essary. Tab. 80 Fault: Oil flows from the compressor air filter after shutdown Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 109: High Moisture Content In The Compressed Air

  There is no voltage or too low a voltage from the generator 9.4.2 Generator voltage too high Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Generator / regulator defective Have repaired. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 110
  Generator faults and alarms Possible cause Remedy Where can I get help? Specialized KAESER- workshop Service Engine speed too high. Have reset to rated speed. Tab. 83 Generator voltage too high Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 111: 10.1 Maintenance

  The following safety concerns relate to any work on components that could be under pressure. ➤ Disconnect the air consumers. ➤ Depressurize all pressurized components and enclosures. ■ Wait until the machine has automatically vented. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 112: Maintenance Schedules

  10.2 Maintenance schedules 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work (e.g. oil and filter changes) at shorter intervals. Adverse conditions are, e.g.: ■…

• Page 113: Regular Maintenance Tasks

  The table below lists regular maintenance tasks. 1. Carry out maintenance tasks punctually taking ambient and operating conditions into consider‐ ation. 2. Change consumables and operating fluids according to each site. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 114
  Check/empty the water trap. 10.3.3 Check fuel lines and hose clamping bands, have replaced if necessary. Have fuel lines and clamps re‐ placed. Engine SM = engine manufacturer’s service manual; SW = specialized workshop. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 115
  Check wheel bolts and nut for tightness. Carry out chassis maintenance. 10.7 Grease the ball coupling, joints 10.7.2 and towbar. Brake maintenance 10.7.3 Engine SM = engine manufacturer’s service manual; SW = specialized workshop. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 116: Tab. 87 Regular Machine Maintenance Tasks

  Option da, db, dc, dd – cyclone separator Clean and check the dirt trap. 10.8.2 Options da, db, dc, dd – compressed air aftercooler Clean the cooler. 10.5.2 EL = qualified electrician; SW = specialist workshop Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 117: Tab. 88 Regular Maintenance Task Options

  Option oe – sealed floor pan Check the machine interior for 10.8.9 liquid accumulations and drain, if required. EL = qualified electrician; SW = specialist workshop Tab. 88 Regular maintenance task options Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 118: Engine Maintenance

  ■ The tank is semi-transparent so the coolant level can be seen from outside. minimum and maximum markings when the engine has ■ The level should be between the cooled down. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 119: Fig. 44 Checking Coolant Level

  Maximum frost protection is ensured with an antifreeze concentration of 55% by volume, as frost protection and heat transfer properties deteriorate beyond this point. Higher concentration also leads to higher operating temperature. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 120: Tab. 89 Kaeser Coolant Mixture Table

  ➤ Follow coolant recommendations in chapter 2.6.4. Preparing coolant Precondition Coolant must meet the specification of ASTM D4985. ➤ The coolant should be mixed in the proportions given by the manufacturer. KAESER coolant mixture table Antifreeze Water Frost protection to [°F] 1 part 2 parts −0.4…

• Page 121
  In machines with chassis (no closed floor pan, no stationary machine), the entire cooling oil of the cooling circuit is drained directly at the engine’s water cooler. This is done from a drain valve with the aid of a separate drain hose. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 122: Fig. 45 Draining The Coolant From The Radiator

  The cooling oil is drained via a pipe which is screwed into the drain opening of the cooler and closed with a shut-off valve. The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 123: Engine Air Filter Maintenance

  Do not use an air filter element with damaged folds or gasket. ■ The use of an unsuitable air filter can permit dirt to ingress the engine and cause prema‐ ture wear and damage. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 124: Fig. 47 Engine Air Filter Maintenance

  Fig. 47 Engine air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 125: Fig. 48 Cleaning The Filter Element

  The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 126: Fuel System Maintenance

  ➤ Keep fuel away from hot machine parts. Fig. 49 Fuel system maintenance Fuel pump Fuel tank Fuel de-watering filter Fuel strainer Fuel pre-filter Fuel fine filter ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 127: Fig. 50 Bleeding The Fuel System

  Fuel filter with water trap maintenance A water trap is installed between the tank and the fuel pump. The separator tank is semi-transpar‐ ent so the fuel level can be seen from outside. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 128: Fig. 51 Fuel Filter With Water Trap Maintenance

  4. Remove the receptacle. 5. Reconnect the battery. 6. Close the door. The mixture of fuel and water and any materials contaminated with fuel must be disposed of in accordance with environment protection regulations. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 129: Fig. 52 Changing The Fuel Pre-Filter

  2. Use a filter wrench to loosen then unscrew the filter cartridge. Catch fuel in the receptacle. 3. Clean the sealing faces of the micro-filter cartridges and the opposite site of the filter mount with lint-free cloth. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 130: Checking The Engine Oil Level

  The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. Engine cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 131: Engine Oil Filling And Topping Up

  See chapter 2.6.5 for engine oil filling volume. The oil dipstick is marked with the «maximum oil level». 1. Open the right-hand access door. 2. Remove the filler cap and fill with fresh oil. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 132: Changing The Engine Oil

  All compressed air consumers are disconnected and the air outlet valves are open. The negative cable to the battery is disconnected. Danger of burns from hot components and escaping engine oil! ➤ Wear long-sleeved clothing and protective gloves. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 133: Fig. 55 Draining The Engine Oil

  The pipe is sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 134: Fig. 56 Draining The Engine Oil (Closed Floor Pan — Stationary Machine)

  Dispose of old oil and oil-soaked working materials according to environmental protection regulations. Further information See chapter 10.3.5 for engine oil filling. Further information regarding changing the engine oil is provided in the engine manufacturer’s op‐ erating manual. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 135: Replace The Engine Oil Filter

  Further information The engine service manual gives further information on oil filter changing. Dispose of old oil filters, old oil and materials contaminated with oil according to environmen‐ tal protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 136: Drive Belt Maintenance

  Removing the belt guard: Fig. 58 Belt guard attachment Belt guard Washer Hexagon bolt Hexagon socket screw 1. Unscrew the securing screws of the belt guard and remove the belt guard. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 137: Fig. 59 Checking The Drive Belt Seating

  The belt tension can be checked by hand: To check the tension, press the belt inwards with the thumb at the mid-point between pulleys. Fig. 60 Manually checking the belt tension Drive belt testing position — Compressive load approximately: 22 Kg Play approximately: 0.28 – 0.35 in Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 138: Fig. 61 Changing/Tensioning The Drive Belt

  1. Loosen the alternator securing screw and clamping nut until the drive belt can be taken off the pulleys. 2. Take off the belt. 3. Check the pulleys for dirt and wear. Dirty pulley: Clean pulley. Worn pulley: Have the pulley changed. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 139: Battery Maintenance

  When working on the battery comply with the following safety signs: A warning label with safety signs is attached to the battery. Fig. 62 Safety signs — warning stickers on the battery. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 140
  The acid quantity is generally sufficient for the life of the battery. Nevertheless, the fluid level should be checked annually. The level should be up to the mark, 0.4 inches above the plates. Replace the battery immediately if the casing leaks. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 141
  ➤ Carry out work on batteries only with the machine shut down. 3. Open the left-hand door. 4. Disconnect the negative cable first, then the positive cable. 5. Unscrew the battery fixing clamp. 6. Replace in the reverse order. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 142: Checking The Fastening Of The Fuel Tank

  10 daN (approx. 25 lbf), slightly hand-tighten only. ➤ Hand-tighten the lashing strip with the integrated ratchet and push the ratchet to the strip. 10.4 Compressor Maintenance ➤ Perform maintenance tasks according to the schedule in chapter 10.2.3.1. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 143: Checking Cooling Oil Level

  2. Slowly unscrew and withdraw the plug from the oil filler port. 3. Check the cooling oil level. Top up if no oil is visible. 4. Replace the plug in the filler port. 5. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 144: Cooling Oil Filling And Topping Up

  5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 145: Changing The Cooling Oil

  Draining the cooling oil (machine with chassis) In machines with chassis (no closed floor pan, no stationary machine), the cooling oil is drained directly at the oil separator tank and the oil cooler. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 146: Fig. 64 Draining The Compressor Cooling Oil

  1. Replace the plug in the oil separator tank filling port. 2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for cooling oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 147: Fig. 65 Draining The Oil From The Heat Exchanger

  The pipes are sealed with a screwed sealing plug at the drain end. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 148: Fig. 66 Draining The Cooling Oil (Closed Floor Pan — Stationary Machine)

  2. Close the door. Dispose of used oil and oil-contaminated working materials according to environmental pro‐ tection regulations. Further information See chapter 10.4.2 for oil filling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 149: Replace The Compressor Oil Filter

  Top up if necessary. 8. Reconnect the negative battery terminal. 9. Close the access door. Dispose of old cooling oil and any materials or parts contaminated with oil according to envi‐ ronment protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 150: Oil Separator Tank Dirt Trap Maintenance

  The negative cable to the battery is disconnected. Fig. 68 Oil separator tank dirt trap maintenance Oil separator tank cover Nozzle Control valve Screw-in connector Union nut Gasket Oil return line Strainer ➤ Open the right-hand access door. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 151: Changing The Oil Separator Cartridge

  The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ and adherence to the changing intervals for: ─ Cooling oil ─ Oil filter ─ Air filter Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 152: Fig. 69 Changing The Oil Separator Cartridge

  2. Pull out the plug to the solenoid valve and withdraw the cable. 3. Unscrew the fitting and turn the air pipe to one side. 4. Remove the screws securing the cover to the tank. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 153
  5. Open the outlet valves. 6. Open the right-hand access door. 7. Check the oil level after about 5 minutes. Top up if necessary. 8. Visually inspect for leaks. 9. Close the access door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 154: Fig. 70 Changing The Oil Separator Cartridge (Option Ba)

  Take particular care with the following components: ■ The frost protector connected to the control line, ■ The oil scavenge line screwed to the underside of the cover. 7. Take out the old cartridge and gaskets Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 155: Compressor Air Filter Maintenance

  Clean the filter according to the maintenance schedule or if the maintenance indicator shows this to be necessary. Renew the air filter element after 2 years at the latest or after it has been cleaned 5 times. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 156: Fig. 71 Compressor Air Filter Maintenance

  Fig. 71 Compressor air filter maintenance Maintenance indicator Filter element Red zone indicator scale Retaining clip Indicating piston of the maintenance indi‐ Filter cap cator Reset knob for the maintenance indicator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 157: Fig. 72 Cleaning The Filter Element

  The yellow piston within the indicator is reset and the maintenance indicator is ready for use again. ➤ Close the doors. Dispose of old parts and contaminated materials according to environmental regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 158: Checking Safety Relief Valves

  Maintenance 10.5 Cleaning the cooler 10.4.8 Checking safety relief valves ➤ Have safety relief valves checked by KAESER Service in accordance with the maintenance schedule. 10.5 Cleaning the cooler The frequency of cleaning is mainly dependent on local operating conditions.

• Page 159: Cleaning The Compressed Air Aftercooler

  2. Visually inspect for leaks. Does oil or cooling water escape? Is a cooler leaking? ➤ Have the defective cooler repaired or replaced immediately by KAESER Service. ➤ Close the doors. Clean the cooler blades only in a washing area equipped with an oil separator.

• Page 160: Maintenance Of Rubber Sealing Strips

  2. Clean the rubber sealing strips with a lint-free cloth and check for cracks, holes and other dam‐ age. Have any damaged gasket replaced. 3. Properly grease the rubber strips. 4. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 161: Chassis Maintenance

  Clean and lubricate all sliding and rotating bearings as necessary but at least every 6 months. Material Lithium-enriched multi-purpose grease Acid-free oil Cleaning cloth Precondition The machine is shut down. The machine is disconnected from the towing vehicle and safely parked. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 162: Fig. 75 Towbar Maintenance

  ➤ If necessary, free the teeth by jerking the towbar horizontally and vertically. ➤ Clean the toothed coupling and smear with water-repellent grease. Further information See chapter 6.4.1 for towbar height adjustment. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 163: Fig. 77 Ball Coupling (Ec Version)

  ■ Oil leaks out. 10.7.2.3 Ball coupling maintenance Option rb/rk/rm/rs, rb/rl/rm/rs, rc/ro/rs Fig. 77 Ball coupling (EC version) Lubricating points Greasing points Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 164: Brake Maintenance

  2. Turn the wheels in the forward direction. 3. Check that there is the same braking resistance on both wheels. Brake resistance not even: adjust brake system. 4. Release the parking brake. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 165: Fig. 79 Checking The Brake Lining Thickness

  3. Apply the parking brake a number of times to centre the brake linings. 4. Use the screwdriver to turn the adjusting wheel back (3 to 5 notches) until there is no more braking resistance to the wheels turning forward. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 166: Fig. 81 Brake Rod Adjustment

  1. To free the brake rod, remove the hexagon nut at the equaliser and loosen the sleeve 2. Clean and grease the brake rod threads. 3. Manually tighten the connecting sleeve. 4. Pull and release the parking brake three times. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 167: Maintenance For Optional Items

  The machine is standing level. The machine is fully vented, the pressure gauge reads 0 psig. The machine has cooled down. All compressed air consumers are disconnected and the air outlet valves are open. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 168: Fig. 82 Tool Lubricator Maintenance

  2. Use a funnel to pour in the oil to the maximum level (0.4 – 0.6 inches below the top of the tank). 3. Check the oil level. 4. Check the filler plug O-ring for external damage. Skadet O-ring: replace the O-ring. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 169: Cyclone Separator Maintenance

  2. Loosen the union nut and detach the condensate drain hose from the dirt trap. 3. Use the small screwdriver to unscrew the nozzle from the dirt trap housing. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 170: Combination Filter Maintenance

  Filter combination is pressurised during operation. Serious injury can result from loosening or opening components under pressure. ➤ Wait until the machine has automatically vented (check: pressure gauge reads 0 psig! ➤ De-pressurise the combination filter. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 171: Fig. 84 Filter Combination

  Pressure differential gauge (check fittings Microfilter for Service personnel) Pre-filter Filter head Cyclone separator Casing gasket Condensate drain hose fittings Filter element Shut-off ball valve for condensate drain‐ Filter housing ➤ Open the left-hand door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 172
  Changing the prefilter element 1. Unscrew the filter housing counter-clockwise. 2. Draw the filter element down and out. 3. Clean the filter head, housing and sealing surface with a lint-free cloth. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 173
  3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open the left-hand door. 6. Check the combination filter housing and hose lines for leaks. 7. Close the door. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 174: Fresh Air Filter Maintenance

  2. Open the condensate drain valve. 3. Close the doors. 4. Switch the machine on and run it in IDLE mode for approx. 2 minutes. The condensate collecting in the filter housings is blown out. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 175
  2. Draw the filter element down and out. 3. Clean the lower housing and sealing surface with a lint-free cloth. 4. Check the housing gasket. When damaged, replace the housing gasket. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 176
  3. Wait until the machine has automatically vented. Pressure gauge reads 0 psig! 4. Open the outlet valves. 5. Open both doors. 6. Check the fresh air filter housing and hose line for leaks. 7. Close the doors. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 177: Frost Protector Maintenance

  Filling the frost protector Frost protector clamp ring Frost protector bowl Antifreeze container 1. Open both doors. 2. Unscrew the clamp ring and remove the bowl. 3. Fill the bowl ¾ full with antifreeze. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 178: Spark Arrestor Maintenance

  Cleaning the spark arrestor (floor pan with service openings) Exhaust silencer end pipe Soot drain port with plug Opening in floor panel to access drain port Exhaust silencer with integrated spark ar‐ restor Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 179: Fig. 89 Cleaning The Spark Arrestor (Sealed Floor Pan)

  7. Remove the hose and replace the plug. 8. Screw the service plug back into the floor pan. It is recommended to blow out the spark arrestor with compressed air once a year. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 180: Engine Air Intake Shut-Off Valve Maintenance

  The machine does not shut down? Destruction of the engine and explosion and/or fire are possible! ➤ Do not move the valve adjusting screw. ➤ Have the valve set by a specialist workshop or KAESER Service. Fig. 90 Engine air intake shut-off valve maintenance…

• Page 181: Generator Drive Belt Maintenance

  Blow out any dirt with compressed air. If necessary, clean the valve with petroleum ether or spirit and allow to dry. Refer to a specialised workshop or KAESER Service if dirt cannot be removed. Checking the engine air intake shut-off valve for correct function and movement: 1.

• Page 182: Fig. 91 Securing The Belt Guard At The Generator

  2. Replace the belt guard. 3. Reconnect the negative battery terminal. 4. Close the doors. 10.8.8.2 Checking belt tension Check belt tension when they are warm, not hot, to avoid length variations through tempera‐ ture. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 183: Fig. 92 Generator Belt Tensioning

  3. Tighten the locknuts 4. Replace the belt guard. 5. Reconnect the negative battery terminal. 6. Close the doors. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 184: Draining Liquid Accumulation Within The Machine

  All compressed air consumers are disconnected and the air outlet valves are open. 1. Place a receptacle underneath the maintenance opening(s). 2. Unscrew and remove the bung(s) from the maintenance openings. The liquid will drain. 3. Clean the bungs and maintenance openings. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 185
  4. Close all maintenance openings with bungs. The machine body is sealed. 5. Using the cleaning cloth, remove any dirt within the machine. Dispose of collected liquid and contaminated working materials according to environmental protection regulations. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 186: Documenting Maintenance And Service Work

  Documenting maintenance and service work Machine model/part number: ➤ Enter maintenance and service work carried out in this list. Date Maintenance task carried out Operating hours Signature Tab. 90 Maintenance log Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 187: 11 Spares, Operating Materials, Service

  11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are match‐ ed to application in our machines and ensure trouble-free operation. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐…

• Page 188: Kaeser Air Service

  Lower costs and higher compressed air availability. 11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Replacement parts for service and repair With the help of the parts list you can plan your material requirement according to operating condi‐…

• Page 189
  ➤ Inspections, preventive maintenance or repair tasks not described in this manual must not be carried out by unqualified personnel. ➤ Have further tasks, not described in this service manual, carried out by motor vehicle workshops or KAESER Service. Operator Manual Screw Compressor No.: 9_6999 23 USE…
• Page 190
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 191
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 192
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 193
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 194
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 195
  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 196
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  Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 239: 12 Decommissioning, Storage And Transport

  Decommissioning of the compressor for several weeks during severe frost Danger of batteries freezing! Discharged batteries are subject to frost damage and can freeze at 14 °F. ➤ Store batteries in a frost-free place. ➤ Store batteries preferably fully charged. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 240: Long-Term Decommissioning And Storage

  ➤ Clean the bodywork and treat with preservative. – ➤ Hang a notice on the instrument panel to inform of the decommis‐ – sioning measures taken. Tab. 96 Long-term decommissioning and storage checklist Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 241: Transport

  Chassis with overrun brake ■ Lighting and signaling system. All other machines may be transported only on non-public roads! National and local regulations must be observed when towing the machine on public high‐ ways. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 242
  Option rb/rk/rm/rs, Adjust the towing bar to suit the height of the towing vehicle hitch. rb/rl/rm/rs When the machine is coupled up, the towing bar must be parallel with the ground. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 243: Fig. 93 Towing Position

  To hitch up the machine, lower the open coupling onto the ball of the towing vehicle so that it clicks into place. The coupling is fully locked when the green locking indicator protrudes and is visible from the side. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 244: Fig. 94 Ball Coupling (Alko-Eu)

  Checking the ball coupling wear indicator (EU version): The ball coupling is equipped with a wear indicator. The wear indicator shows: ■ Wear on the ball hitch. ■ Wear on the coupling. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 245: Fig. 95 Wear Alert, Ball Coupling (Alko-Eu)

  Option rd/ro/rs Coupling machine with ball coupling (US version): To couple up the compressor, lower the open coupling onto the ball hitch of the towing vehicle so that it clicks into place. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 246: Fig. 96 Ball Coupling (Alko-Usa)

  Ensure transport readiness of the coupled machine. Fig. 97 Release the parking brake. Parking brake with gas spring assistance Parking brake with ratchet and spring load‐ Parking brake lever Dead point zone Brake lever release button Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 247: Fig. 98 Automatic Jockey Wheel In Transport Position

  (see Ill. 97, figure b). ■ Pull the brake lever a little further on and press the release button. ■ Hold in the release button and push the lever fully down. 6. Remove the chocks. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 248: Fig. 99 Safety Sign — Secure The Chocks

  5. Attach the lighting and indicator systems and carry out a function check. 6. Remove the chocks and secure them in the transport securing device. Replacement chocks can be purchased from KAESER representatives. A list is given at the end of this manual. The part number of the chock is 5.1325.0.

• Page 249: Fig. 100 Breakaway Cable Attachment

  ➤ Attach safety chains to the towing vehicle. ■ Both chains must be crossed under the ball coupling/towing eye. ■ Allow slack for towed machine to turn. ■ Attach chain hooks securely to tow vehicle frame. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 250: Parking The Machine

  ➤ Wind the automatic jockey wheel up only as far as the bead does not touch the cam. ➤ Do not place your feet beneath the towing device. Fig. 102 Warning «Injury can occur if the towbar is allowed to fall.» Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 251: Fig. 103 Towbar With Automatic Jockey Wheel

  Slowly forward the towing vehicle to separate from the parked machine. Option rb/rk/rm/rs, Parking the machine (height-adjustable chassis): rb/rl/rm/rs 1. Use a coupled towing vehicle to move the machine into position. 2. Disconnect the lighting and signaling cable. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 252: Fig. 105 Safety Sign — Secure The Chocks

  ➤ As a general rule, the machine should always be blocked with chocks when it is not being moved. ➤ The machine should not be manoeuvred by hand. 2. Use a coupled towing vehicle to move the machine into position. Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 253: Transport With A Crane

  ➤ Do not set down unevenly. 2. Set the machine down slowly and carefully. 12.2.5 Option rw Transport with a forklift truck Precondition The machine is shut down. All connecting lines and hoses disconnected and removed. Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 254: Transporting The Machine As Load

  Packing and securing methods must be such that, assuming proper handling, the goods arrive in perfect condition at the destination. Additional measures must be taken for the transport of machines by sea or air. Please contact KAESER SERVICE for more information. Material Chocks…

• Page 255: Storage

  3. The loads must be secured against rolling, tipping, slipping and falling. Contact KAESER Service with any questions regarding transporting or load securing. KAESER accepts no liability and provides no guarantee for damage arising from incorrect transport or insufficient or incorrect load securing provisions.

• Page 256: Disposal

  Decommissioning, Storage and Transport 12.4 Disposal Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. Moisture and frost can damage the machine! ➤ Prevent ingress of moisture and formation of condensation. ➤ Maintain a storage temperature of >32 °F.

• Page 257: 13 Annex

  Fig. 108 Identification Machine nameplate with serial number Options label VIN* (stamped in the bodywork) Engine nameplate with serial number *Vehicle Identification Number 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 258
  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.2 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 263: Dimensional Drawings

  Dimensional drawings 13.3.1 Option rb/rm/rs Dimensional drawing, chassis options ■ Option rb — Chassis EU version ■ Option rm — Chassis with height-adjustable towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 264
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 265: Dimensional Drawing, Chassis Options

  13.3.2 Option rc/ro/rs Dimensional drawing, chassis options ■ Option rc — Chassis GB version ■ Option ro — Chassis with fixed height towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 266
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 267: Dimensional Drawing, Chassis Options

  13.3.3 Option rd/ro/rs Dimensional drawing, chassis options ■ Option rd — Chassis USA version ■ Option ro — Chassis with fixed height towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 268
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 269: Dimensional Drawing, Chassis Options

  Option rb — Chassis EU version ■ Option rl — Chassis with higher axle load ■ Option rm — Chassis with height-adjustable towbar ■ Option rs — Chassis with overrun brake Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 270
  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 271: Dimensional Drawing, Stationary Version

  Annex 13.3 Dimensional drawings 13.3.5 Option rw Dimensional drawing, stationary version ■ Option rw — Skid frame on runners Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 273: Dimensional Drawing, Stationary Version

  Annex 13.3 Dimensional drawings 13.3.6 Option rx Dimensional drawing, stationary version ■ Option rx — On frame Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.3 Dimensional drawings Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 275: Wiring Diagrams

  Annex 13.4 Wiring diagrams 13.4 Wiring diagrams 13.4.1 Electrical Diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 289: Lighting And Signaling System Connection

  Annex 13.4 Wiring diagrams 13.4.2 Option tc Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 297: Lighting And Signaling System Connection

  Annex 13.4 Wiring diagrams 13.4.3 Option te Lighting and signaling system connection Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 302: Generator Electrical Diagram, 400V, 3-Ph

  Annex 13.4 Wiring diagrams 13.4.4 Option ga Generator electrical diagram, 400V, 3-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 311: Generator Electrical Diagram, 230V, 3-Ph

  Annex 13.4 Wiring diagrams 13.4.5 Option ga Generator electrical diagram, 230V, 3-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 320: Generator Electrical Diagram, 115 V, 2-Ph

  Annex 13.4 Wiring diagrams 13.4.6 Option ga Generator electrical diagram, 115 V, 2-ph Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 329: Generator Electrical Diagram, 230 V, 2-Ph

  Annex 13.4 Wiring diagrams 13.4.7 Option ga Generator electrical diagram, 230 V, 2-ph Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

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• Page 337
  Annex 13.4 Wiring diagrams Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 338: Fuel Circulation Diagram

  Annex 13.5 Fuel circulation diagram 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 339
  Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 340
  Annex 13.5 Fuel circulation diagram Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 341: Assembly Diagrams — Chassis

  Annex 13.6 Assembly diagrams — chassis 13.6 Assembly diagrams — chassis 13.6.1 Assembly diagrams — chassis EU version Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 342
  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 343: Assembly Diagrams — Chassis Gb/Us Version

  Annex 13.6 Assembly diagrams — chassis 13.6.2 Assembly diagrams — chassis GB/US version Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
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  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
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  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 346: Assembly Diagram Brake Rod

  Annex 13.6 Assembly diagrams — chassis 13.6.3 Assembly diagram brake rod Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 347
  Annex 13.6 Assembly diagrams — chassis Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 348: Operating Instructions For Compressed Air Filter (Combination Filter)

  Annex 13.7 Operating instructions for compressed air filter (combination filter) 13.7 Option dd Operating instructions for compressed air filter (combination filter) Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 349
  FA (D), FB (D&E), FC (D&E), FD (E), FE (D&E), FF (D&E), FG STANDARD D-Pack D-PACK E-PACK Basic (OPTION) (OPTION) (OPTION) Kaeser Kompressoren GmbH Postfach 2143 96410 Coburg Tel.: 09561/640-0 Fax: 09561/640130 http://www.kaeser.com , 2 . 3 . 9 n u t…
• Page 350
  E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 2 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 351
  E-Pack: Filter mit Filtermonitor E-Pack: Filter with filtermonitor Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 3 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 352
  E-pack: Filter with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 4 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 353
  E-pack: Filter series FF with filtermonitor and ECO-DRAIN Anzahl Filterelemente siehe Kapitel 3. „Technische Daten“. Quantity of filter cartridges see chapter 3. „Technical data“. — 5 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 354
  We reserve the right to alter the specifications without prior notice Technische Änderungen vorbehalten. — 6 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 355
  Ausführende Tätigkeit. Changes sequence of operation Vom Bediener auszuführende Bedienschritte. 1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the filter — 7 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 356
  ∗ Es besitzt als solches eine zur Inbetriebnahme und War- tung derartiger Einrichtungen befähigende Ausbildung bzw. Berechtigung. — 8 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 357
  Filter/ -systeme zur Aufbereitung von Atemluft dürfen nur nach approved from manufacturer. Genehmigung des Herstellers der Filter/ -systeme eingesetzt und betrieben werden. — 9 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 358
  Annex 13.7 Operating instructions for compressed air filter (combination filter) 3. Technical data 3. Technische Daten — 10 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 359
  The coalesced liquids then drain to the bottom of Coalescings ausgefiltert. Die Luft tritt durch den perforierten äuße- the cartridge for removal. ren Stützmantel aus. — 13 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 360
  Filters und tropfen dann in den Filterbehälter ab. downstream to the bottom of the sleeve and drain to the bottom of the filter bowl. — 15 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 361
  Bei den Filtern FD, FG entfällt der Kondensatableitungsanschluß. Condensate drain does not exist in filters FD, FG. — 21 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 362
  Close the shut-off device in the bypass (if installed). Das Filter/ -system ist nun in BETRIEB. The filter/ -system is now OPERATIVE. — 24 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 363
  (Siehe Kapitel 9) The FG filter does not require a differential pressure gauge. Das Filter FG benötigt keine Differenzdruckanzeige. — 25 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 364
  F r e t i t a Bh = Kompressor-Betriebsstunden / Working hours — 32 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 365
  The filter(s) contain(s) systems under high pressure. hende Systeme. Alle pressure must be let off before servicing Vor Servicearbeiten sind sie drucklos zu machen. — 33 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 366
  Place filter under pressure again by slowly opening the Filter durch langsames Öffnen der Absperrvorrichtungen shut-off device. wieder mit Druck beaufschlagen. — 34 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 367
  ß i s l i Nähere Informationen finden Sie auch im Anhang ECO DRAIN. For more details please see annexe ECO DRAIN. — 35 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 368
  Personen unsachgemäß geöffnet oder repariert wurde und/oder mechanische Beschädigungen irgendwelcher Art aufweist. — 36 — t l l FI HANK-MOB_02 D E Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 369: Operating Instructions For Compressed Air Filter (Fresh Air Filter)

  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) 13.8 Option dc Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…

• Page 370
  ALYVOS GARŲ IR KVAPO ŠALINIMO FILTRAI ФИЛЬТРЫ ДЛЯ УСТРАНЕНИЯ ЗАПАХА И ПАРОВ МАСЛА FILTRI ZA ODSTRANJEVANJE OLJNIH HLAPOV IN VONJAV YAĞ BUHARI VE KOKUSU GİDERİCİ FİLTRELER FILTRI LI JNE{{U L-FWAR TA}-}JUT U L-IRWEJJA{ FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 371
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 372
  Указывает на требования по уничтожению использованных деталей и отходов • Označuje zahteve za odlaganje rabljenih delov in odpadkov. • Kullanılmış parçaların ve atıkların atılmasına ilişkin gereklilikleri vurgular • Tissottolinea l-kundizzjonijiet biex wie[ed jarmi l-partijiet u]ati u l-iskart FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 373
  • Įsitikinkite, kad naudojamas reikiamas įrankis • Убедитесь, что используется правильный инструмент • Poskrbite, da boste uporabili ustrezno orodje • Doğru alet kullanılmasını sağlayın • Kun ]gur li tintu]a l-g[odda t-tajba FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 374
  A instalação e a manutenção deste produto só deve ser realizada por pessoal autorizado e competente, sob estrita observância destas instruções de utilização e de quaisquer normas e requisitos legais relevantes, quando adequado. Conserve este guia do utilizador para referência futura FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 375
  I huma ffittjati b’indikatur tal-volum ta]-]ejt. Kemm l-elementi tal-filtru kif ukoll l-indikatur g[andhom jinbidlu jekk l- indikatur isir ta’ kulur blu. Jekk Jog[;bok Innota — Dan hu indikatur tal-volum ta]-]ejt u ma jindikax i]-]mien li jdum iservi l-element tal-filtru. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 376
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 1/4” 1/2” FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 377
  020 C 020 D 020AA 020AC 020 E 025AA 025DAC 025 D 025AA 025EAC 025 E 030 E BOIE1 AC010 I — AC030 030AA 030AC 030 F 030 G FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 378
  I sono provvisti di un indicatore degli oli misti. Sostituire gli elementi filtranti e l’indicatore quando il secondo assume una colorazione blu. Nota — L’indicatore segnala la presenza di oli misti, ma non la durata dell’elemento filtrante. FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 379
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 0 bar 0 bar 0 psi 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 380
  13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 0 bar 0 psi 0 bar 0 bar 0 psi 0 psi 0 bar 0 psi FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…
• Page 381
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 FILTER-DH-OIL-XEVOLUTION 01 Operator Manual Screw Compressor No.: 9_6999 23 USE M100…
• Page 382
  Annex 13.8 Operating instructions for compressed air filter (fresh air filter) AC010 — AC030 Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

• Page 383: Service Tasks — Generator

  In order to ensure a safe operation of the machine, the generator must be inspected once every year by a trained and authorized electrician. Have the following tasks performed by a specialist electrician or an authorized KAESER service representative: ■…

• Page 384
  Annex 13.9 Service tasks — Generator Operator Manual Screw Compressor M100 No.: 9_6999 23 USE…

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Contents

4.3

4.4

4.4.1

Machine operating modes ……………………………………………………………………….

4.4.2

Control modes ……………………………………………………………………………………….

4.5

Options ……………………………………………………………………………………………………………..

4.5.1

4.5.2

Machine mountings …………………………………………………………………………………

4.5.3

5.1

Ensuring safety ………………………………………………………………………………………………….

5.2

Installation conditions ………………………………………………………………………………………….

5.2.1

5.2.2

5.2.3

Exhaust duct design ……………………………………………………………………………….

5.3

6.1

Ensuring safety ………………………………………………………………………………………………….

6.2

Reporting Transport Damage ……………………………………………………………………………….

6.3

6.4

6.5

6.6

Options ……………………………………………………………………………………………………………..

6.6.1

Anchoring the machine ……………………………………………………………………………

6.6.2

7.1

Ensuring safety ………………………………………………………………………………………………….

7.2

7.3

7.4

7.5

7.6

7.7

7.8

Setting the set point pressure ………………………………………………………………………………

7.9

8.1

Switching on and off ……………………………………………………………………………………………

8.1.1

Switching on ………………………………………………………………………………………….

8.1.2

Switching off ………………………………………………………………………………………….

8.2

8.3

8.4

8.5

8.6

9.1

Basic instructions ……………………………………………………………………………………………….

9.2

Other faults ………………………………………………………………………………………………………..

10.1 Ensuring safety ………………………………………………………………………………………………….

Operating Manual

Rotary screw compressor

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901848 21 E

Manual Kaeser Csdx t

Short Description

Instruction manual for Kaeser CSDX T screw compressor.

Description

Инструкция по эксплуатации Винтовой компрессор CSDX T

KAESER KOMPRESSOREN 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com

Оригинал инструкции /KKW/SCSDX 2.02 ru SBA-SCHRAUBEN-T-SC /KKW/SSC 2.02 20120417 134352

К этому документу 1.1 Порядок обращения с документом . 1.2 Дополнительные документы . 1.3 Авторское право . 1.4 Символы и условные обозначения . 1.4.1 Указания по предупреждению . 1.4.2 Предупреждения нанесения материального ущерба . 1.4.3 Дополнительные указания и символы .

Технические характеристики 2.1 Фирменная табличка . 2.2 Опции . 2.3 Вес . 2.4 Температура . 2.5 Окружающие условия . 2.6 Вентиляция . 2.7 Давление . 2.8 Производительность . 2.9 Рекомендуемые охлаждающие масла . 2.10 Количество заливаемого охлаждающего масла . 2.11 Двигатели и мощность . 2.11.1 Двигатель компрессора . 2.11.2 Двигатель вентилятора . 2.11.3 Двигатель вентилятора . 2.12 Звуковое излучение [дБ(А)] . 2.13 Электрическое питание . 2.14 Характеристики электрического подключения . 2.14.1 Частота сети: 50 Гц . 2.14.2 Частота сети: 1000 м . 2.15 Водяное охлаждение . 2.15.1 Водяное охлаждение (пластинчатый теплообменник) . 2.15.2 Водяное охлаждение (трубчатый теплообменник) . 2.16 Система рекуперации тепла . 2.16.1 Подготовка для внешней системы рекуперации тепла . 2.16.2 Внутренняя система рекуперации тепла . 2.17 Холодоосушитель .

4 4 5 5 5 6 6 7 7 10 11 11 12 12 13 13 14 14 15 16 17 19 20 20 21 22

Техника безопасности и ответственность 3.1 Основополагающие сведения . 3.2 Применение по назначению . 3.3 Применение не по назначению . 3.4 Ответственность пользователя . 3.4.1 Cоблюдение законодательных предписаний и общепризнанных правил . 3.4.2 Определение персонала . 3.4.3 Соблюдение сроков технического освидетельствования и правил по профилактике несчастных случаев . 3.5 Источники опасности . 3.5.1 Безопасное обращение с источниками опасности . 3.5.2 Безопасное применение машины . 3.5.3 Организационные мероприятия . 3.5.4 Опасные зоны . 3.6 Предохранительные устройства . 3.7 Знаки безопасности . 3.8 В аварийной ситуации . 3.8.1 Правильные действия в случае возникновения пожара .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

24 24 24 25 25 25 26 26 26 29 31 31 32 32 34 34

3.8.2 Оказание помощи при травмировании охлаждающим маслом . 3.8.3 Оказание помощи при поражении или отравлении хладагентом . 3.9 Гарантия . 3.10 Охрана окружающей среды .

Устройство и принцип действия 4.1 Корпус . 4.2 Принцип действия машины . 4.2.1 Холодоосушитель . 4.2.2 Беспотенциальные контакты . 4.3 Параметры . 4.3.1 Прикручивающиеся опоры машины . 4.3.2 Водяное охлаждение . 4.3.3 Фильтровальный мат для охлаждающего воздуха . 4.3.4 Система рекуперации тепла . 4.4 Рабочие режимы и виды регулирования . 4.4.1 Рабочие режимы машины . 4.4.2 Виды регулирования . 4.5 Виды регулирования холодоосушителя . 4.6 Предохранительные устройства . 4.7 Панель управления SIGMA CONTROL 2 .

37 37 39 39 39 39 40 40 41 42 42 43 44 45 46

Условия установки и эксплуатации 5.1 Обеспечение техники безопасности . 5.2 Условия в месте установки . 5.2.1 Определение места для установки и расстояний . 5.2.2 Обеспечение вентиляции машинного помещения . 5.2.3 Проектирование канала отточной вентиляции . 5.3 Эксплуатация машины подключенной к пневмосети .

Монтаж 6.1 Обеспечение техники безопасности . 6.2 Информирование о повреждениях при транспортировке . 6.3 Подключение машины к сети сжатого воздуха . 6.4 Электрическое подключение . 6.4.1 Холодоосушитель: согласование с напряжением сети . 6.5 Подсоединение системы отвода конденсата . 6.6 Опции . 6.6.1 Крепление машины . 6.6.2 Подсоединение системы водяного охлаждения . 6.6.3 Подсоединение системы рекуперации тепла .

53 54 54 55 55 56 57 57 57 58

Ввод в эксплуатацию 7.1 Обеспечение техники безопасности . 7.2 Перед вводом в эксплуатацию . 7.3 Контроль выполнения требований монтажа и эксплуатации . 7.4 Установка магнитного пускателя . 7.5 Регулировка защитного автомата двигателя . 7.6 Заливка охлаждающего масла в компрессорный блок . 7.7 Включение и выключение регулирования ЧАСТИЧНОЙ НАГРУЗКИ . 7.8 Первое включение машины . 7.9 Установка заданного давления сети . 7.10 Изменение языка индикации .

60 61 61 62 62 63 64 65 66 66

Эксплуатация 8.1 Включение и выключение . 8.1.1 Включение .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

8.1.2 Выключение . Включение и выключение в аварийной ситуации . Включение и выключение с дистанционного пульта . Включение и выключение при помощи таймера . Эксплуатационные сообщения . Квитирование сообщений о неисправностях и предупреждениях .

Распознавание ошибок и их устранение 9.1 Основополагающие сведения . 9.2 Прочие неисправности .

Техническое обслуживание 10.1 Обеспечение техники безопасности . 10.2 Соблюдение сроков техобслуживания . 10.2.1 Документирование работ по техобслуживанию . 10.2.2 Возврат счетчика часов технического обслуживания в исходное положение . 10.2.3 Регулярные работы по техобслуживанию . 10.2.4 Интервалы замены охлаждающего масла . 10.2.5 Регулярные профилактические работы . 10.3 Очистка или замена фильтровального мата распределительного шкафа . 10.4 Техобслуживание радиатора . 10.5 Техобслуживание системы водяного охлаждения . 10.6 Очистка или замена фильтровального мата охлаждающего воздуха . 10.7 Техобслуживание системы рекуперации тепла . 10.7.1 Внешняя система рекуперации тепла . 10.7.2 Внутренняя система рекуперации тепла . 10.8 Замена воздушного фильтра . 10.9 Техобслуживание двигателей . 10.10 Проверка муфты сцепления . 10.11 Проверка предохранительного клапана . 10.12 Проверка предохранительного отключения при повышенной температуре . 10.13 Проверка уровня охлаждающего масла . 10.14 Сброс давления из машины . 10.15 Доливка охлаждающего масла . 10.15.1 Сброс давления из машины . 10.15.2 Доливка охлаждающего масла и проведение пробного запуска . 10.16 Замена охлаждающего масла . 10.17 Замена сменного элемента масляного фильтра . 10.18 Заменить сменный элемент маслоотделителя . 10.19 Техобслуживание холодоосушителя . 10.19.1 Очистка конденсатора . 10.19.2 Техобслуживание системы отвода конденсата . 10.20 Документирование работ по профилактике и техобслуживанию .

76 78 79 79 80 81 82 83 83 83 83 84 85 86 87 88 88 90 91 92 93 98 99 101 102 102 104

Запасные части, эксплуатационные вещества, техническое обслуживание 11.1 Обратите внимание на фирменную табличку . 11.2 Заказ запасных частей и эксплуатационных материалов . 11.3 KAESER AIR SERVICE . 11.4 Координаты сервисных центров . 11.5 Запасные части для профилактики и ремонта .

Снятие с эксплуатации, складирование и транспортировка 12.1 Снятие с эксплуатации . 115 12.2 Упаковка . 115 12.3 Хранение . 116

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

12.4 Транспортировка . 12.4.1 Безопасность . 12.4.2 Транспортировка машины с помощью вилочного погрузчика . 12.4.3 Транспортировка машины с помощью крана . 12.5 Утилизация . 13

Приложение 13.1 Технологическая схема трубопроводов и инструментов (R+I — схема) . 13.2 Технологическая схема трубопроводов и инструментов (R+I-схема) Регулирование ЧАСТИЧНОЙ НАГРУЗКИ . 13.3 Габаритный чертеж . 13.4 Электрическая схема .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

116 116 116 117 117 119 125 131 135

Винтовой компрессор 9_9519 02 R

Рис. 1 Рис. 2 Рис. 3 Рис. 4 Рис. 5 Рис. 6 Рис. 7 Рис. 8 Рис. 9 Рис. 10 Рис. 11 Рис. 12 Рис. 13 Рис. 14 Рис. 15 Рис. 16 Рис. 17 Рис. 18 Рис. 19 Рис. 20 Рис. 21 Рис. 22 Рис. 23 Рис. 24 Рис. 25 Рис. 26 Рис. 27 Рис. 28 Рис. 29 Рис. 30 Рис. 31 Рис. 32 Рис. 33 Рис. 34 Рис. 35 Рис. 36 Рис. 37 Рис. 38 Рис. 39 Рис. 40 Рис. 41 Рис. 42 Рис. 43 Рис. 44 Рис. 45 Рис. 46

Максимальная относительная влажность всасываемого воздуха . Расположение знаков безопасности . Изображение корпуса . Изображение машины . Холодоосушитель . Прикручивающаяся опора машины . Водяное охлаждение (опция K2) . Водяное охлаждение (опция K9) . Фильтровальный мат для охлаждающего воздуха (опция K3) . Внутренняя система рекуперации тепла (опция W2/W3) . Изображение кнопок . Обзор индикаторов . RFID-считывающее устройство . Рекомендации по установке, размеры [мм] . Воздухопровод . Система отвода конденсата, размеры [мм] . Подсоединение системы водяного охлаждения . Подсоединение системы рекуперации тепла . Заливное отверстие на впускном клапане . Муфта сцепления . Регулирование ЧАСТИЧНОЙ НАГРУЗКИ: положения запорного крана . Включение и выключение . Выключение в аварийной ситуации . Включение и выключение с дистанционного пульта . Включение и выключение при помощи таймера . Квитирование сообщений . Вентиляция распределительного шкафа . Очистка радиатора . Фильтровальный мат для охлаждающего воздуха . Техобслуживание воздушного фильтра . Техобслуживание двигателей . Проверка муфты сцепления . Проверка уровня охлаждающего масла . Сброс давления из машины . Доливка охлаждающего масла . Замена охлаждающего масла, маслоотделитель . Замена охлаждающего масла, масляный радиатор . Замена охлаждающего масла, блок компрессора . Замена охлаждающего масла, система рекуперации тепла . Замена масляного фильтра . Заменить сменный элемент маслоотделителя . Холодоосушитель . Проверить устройство отвода конденсата . Техобслуживание устройства отвода конденсата . Транспортировка вилочным погрузчиком . Транспортировка с помощью крана .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

6 32 37 38 39 39 40 40 41 42 46 47 48 51 54 56 57 59 63 64 65 67 68 69 70 71 80 81 82 84 85 86 88 89 91 94 96 96 97 99 100 101 102 103 116 117

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Таб. 1 Таб. 2 Таб. 3 Таб. 4 Таб. 5 Таб. 6 Таб. 7 Таб. 8 Таб. 9 Таб. 10 Таб. 11 Таб. 12 Таб. 13 Таб. 14 Таб. 15 Таб. 16 Таб. 17 Таб. 18 Таб. 19 Таб. 20 Таб. 21 Таб. 22 Таб. 23 Таб. 24 Таб. 25 Таб. 26 Таб. 27 Таб. 28 Таб. 29 Таб. 30 Таб. 31 Таб. 32 Таб. 33 Таб. 34 Таб. 35 Таб. 36 Таб. 37 Таб. 38 Таб. 39 Таб. 40 Таб. 41 Таб. 42 Таб. 43 Таб. 44 Таб. 45 Таб. 46 Таб. 47 Таб. 48 Таб. 49 Таб. 50 Таб. 51 Таб. 52 Таб. 53

Степени опасности и их значение (опасность для персонала) . Степени опасности и их значение (материальный ущерб) . Фирменная табличка . Опции . Вес машины . Температура . Окружающие условия . Вентиляция . Давление срабатывания предохранительного клапана (50Гц) . Давление срабатывания предохранительного клапана (60Гц) . Производительность (50 Гц) . Производительность (60 Гц) . Рекомендуемые охлаждающие масла . Рекомендуемые охлаждающие масла (для пищевой промышленности) . Рекомендуемые охлаждающие масла (машины для снежных пушек) . Количество заливаемого охлаждающего масла (опция K1) . Количество заливаемого охлаждающего масла (опция K2) . Количество заливаемого охлаждающего масла (опция K9) . Количество заливаемого охлаждающего масла (опция W1) . Количество заливаемого охлаждающего масла (опция W2) . Количество заливаемого охлаждающего масла (опция W3) . Двигатель компрессора (50Гц) . Двигатель компрессора (60Гц) . Двигатель вентилятора (опция K1) . Двигатель вентилятора (опция K2/K9; 50Гц) . Двигатель вентилятора (опция K2/K9; 60Гц) . Звуковое излучение [дБ(А)] . Характеристики подключения 200В/3/50Гц . Характеристики подключения 230В/3/50Гц . Характеристики подключения 400В/3/50Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Характеристики подключения 460В/3/60Гц . Температура охлаждающей воды (ΔT=10K) . Температура охлаждающей воды (ΔT=30K) . Спецификация: Теплообменник (опция K2) . Качество охлаждающей воды . Температура охлаждающей воды (ΔT=10K) . Температура охлаждающей воды (ΔT=30K) . Спецификация: теплообменника (опция K9) . Качество охлаждающей воды . Тепловая мощность (опция W1) . Качество охлаждающей воды . Спецификация: Теплообменник (опции W2/W3) . Тепловая мощность (опции W2/W3) . Объемный поток/потеря давления (опция W2) . Объемный поток/потеря давления (опция W3) . Холодоосушитель: Πневмосистема . Холодоосушитель: Cистема циркуляции хладагента . Сроки технического освидетельствования в соответствии правил безопасной эксплуатации . Опасные зоны . Знаки безопасности .

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

1 2 4 4 5 5 5 6 6 7 7 7 8 8 9 10 10 10 11 11 11 11 12 12 12 13 13 14 15 15 15 15 16 16 17 17 18 18 19 19 19 20 20 21 21 22 22 22 22 23 26 31 33

Таб. 54 Таб. 55 Таб. 56 Таб. 57 Таб. 58 Таб. 59 Таб. 60 Таб. 61 Таб. 62 Таб. 63 Таб. 64 Таб. 65 Таб. 66 Таб. 67 Таб. 68 Таб. 69 Таб. 70 Таб. 71

Энергосберегающие виды регулирования . 43 Рабочие режимы при виде регулирования ЧАСТИЧНАЯ НАГРУЗКА . 44 Виды регулирования холодоосушителя . 45 Кнопки . 46 Индикаторы . 47 RFID-считывающее устройство . 49 Ввод в эксплуатацию после длительного хранения/перерыва в работе . 61 Чек-лист проверки требований монтажа . 61 Регулирование ЧАСТИЧНОЙ НАГРУЗКИ: положения запорного крана . 64 Обозначение на машине . 69 Обозначение на дистанционном пульте . 69 Обозначение на машине . 70 Прочие неисправности и меры устранения . 73 Регулярные работы по техобслуживанию . 77 Охлаждающее масло: интервалы замен . 78 Регулярные профилактические работы . 79 Зарегистрированные работы по техническому обслуживанию . 104 Запасные части для техобслуживания машины . 105

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Порядок обращения с документом

Порядок обращения с документом Инструкция по эксплуатации является составной частью изделия. В ней описано состояние машины на момент поставки заводом-изготовителем. ➤ Храните инструкцию по эксплуатации в течение всего срока службы машины. ➤ Передавайте инструкцию по эксплуатации каждому последующему владельцу или по‐ льзователю. ➤ Обеспечьте внесение в инструкцию по эксплуатации всех изменений. ➤ Внесите данные фирменной таблички и индивидуальные особенности комплектации ма‐ шины в таблицу в разделе 2.

Дополнительные документы Вместе с инструкцией по эксплуатации Вы получите дополнительные документы: ■

Свидетельство о приемке/инструкция по эксплуатации ресивера

Декларация о соответствии требованиям действующих директив

Инструкция по пользованию SIGMA CONTROL 2

Отсутствующие документы могут быть заказаны на фирме KAESER. ➤ Проверьте комплектность документов и соблюдайте содержащиеся в них указания. ➤ При заказе дополнительных документов, просим непременно указать данные фирменной таблички.

Авторское право Данная инструкция по эксплуатация защищена авторскими правами. По вопросам относи‐ тельно применения и размножения документации обращайтесь к фирме KAESER. Мы охот‐ но окажем Вам содействие в отношении соответствующего использования информации.

Символы и условные обозначения ➤ Обратите внимание на символы и обозначения, приведенные в данной инструкции.

Указания по предупреждению Указания по предупреждению предупреждают о возможной опасности для персонала, воз‐ никшей в результате несоблюдения соответствующих мероприятий. Предупреждающие указания подразделены на три степени опасности, которые Вы можете распознать по сигнальному слову:

Предупреждает о непосред‐ В результате тяжелые телесные ственно угрожающей опасно‐ повреждения или смертельный исход сти

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Последствия при несоблюдении

Символы и условные обозначения

Последствия при несоблюдении

ПРЕДУПРЕЖДЕНИЕ Предупреждает о возможной Возможны тяжелые телесные повреж‐ угрожающей опасности дения или смертельный исход ОСТОРОЖНО Таб. 1

Предупреждает о возможной Возможны легкие телесные повреж‐ опасной ситуации дения

Степени опасности и их значение (опасность для персонала) Предупреждающие указания, находящиеся в начале раздела, распространяются на весь раздел и все его подразделы. Пример: ОПАСНО Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждающих указа‐ ний. Сигнальное слово «ОПАСНО» означает, что несоблюдение этих указаний может при‐ вести к тяжелым телесным повреждениям или смертельному исходу. ➤ Здесь описаны мероприятия, с помощью которых Вы можете защитить себя от опасности. Предупреждающие указания, распространяющиеся на подразделы или руководство к дей‐ ствию, приведены непосредственно в них и их очередность пронумерована. Пример: 1. ПРЕДУПРЕЖДЕНИЕ! Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждающих указаний. Сигнальное слово «ПРЕДУПРЕЖДЕНИЕ» означает, что несоблюдение этих указаний мо‐ жет привести к тяжелым телесным повреждениям или смертельному исходу. ➤ Здесь описаны мероприятия, с помощью которых Вы можете защитить себя от опас‐ ности. 2. Внимательно прочитать предупреждающие указания и всегда соблюдать их.

Предупреждения нанесения материального ущерба В отличии от предупреждающих указаний в данном случае речь не идет об опасности для персонала. Предупреждения о нанесении материального ущерба Вы можете распознать по сигнальному слову:

Сигнальное слово Значение

Последствия при несоблюдении

Возможен материальный ущерб

Предупреждает о возможной опасной ситуации

Степени опасности и их значение (материальный ущерб) Пример:

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Символы и условные обозначения

УКАЗАНИЕ Здесь описаны виды и источники угрожающей опасности! Здесь описаны возможные последствия при несоблюдении предупреждений. ➤ Здесь описаны мероприятия, с помощью которых можно предотвратить нанесение материального ущерба. ➤ Внимательно прочитать предупреждения и неукоснительно соблюдать их.

Дополнительные указания и символы Этот символ указывает на важную информацию.

Материал Обязательное условие

Здесь указаны данные о специальном инструменте, эксплуатационных материалах или за‐ пасных частях. Здесь описаны обязательные условия для осуществления каких-либо действий. В данном случае могут указываться меры безопасности, которые помогут Вам предотвра‐ тить возникновение опасных ситуаций.

➤ Этот символ указывает на руководство к действию, состоящее только из одного шага. Если действия совершаются посредством нескольких шагов, их очередность пронумеро‐ вана. Информация, касающаяся только одной опции, имеет буквенно-цифровое обозначение (например: Н1 означает, что этот раздел распространяется только на машины с возмож‐ ностью крепления опор к полу). Буквенно-цифровые обозначения, встречающиеся в дан‐ ной инструкции, пояснены в разделе 2.2. Информация о потенциальных проблемах обозначена с помощью вопросительного знака. Во вспомогательном тексте указывается причина . ➤ . и дается рекомендация по ее устранению. Этот символ указывает на важную информацию или мероприятия по охране окружаю‐ щей среды.

Здесь обращают Ваше внимание на последующее описание данной темы.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

2 Технические характеристики 2.1

Фирменная табличка На фирменной табличке Вы найдете основные технические данные и модель машины. Фирменная табличка находится снаружи машины: ■

➤ Укажите здесь данные фирменной таблички: Наименование

Винтовой компрессор Артикульный номер Серийный номер Год выпуска Номинальная мощность Номинальное число оборотов двигателя Максимальное избыточное рабочее давление Окружающая температура Таб. 3

Опции Перечень возможных опции приведен в таблице. ➤ Укажите дополнительную комплектацию в графе о наличии: Опция

Регулирование частичной нагрузки

Прикручивающиеся опоры машины

Водяное охлаждение (пластинчатый теплообменник)

Фильтровальный мат для охлаждающего воздуха

Водяное охлаждение (трубчатый теплообменник)

Электропитание холодоосушителя через транс‐ форматор

Подготовка для системы рекуперации тепла

Система рекуперации тепла ΔT=25 K

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Система рекуперации тепла ΔT=55 K Таб. 4

Указанный вес является максимальным весом. Действительный вес машины зависит от ин‐ дивидуального оснащения. CSDX 140

Минимальная темпера‐ тура включения [°C]

Рабочая конечная тем‐ пература сжатия [°C]

Максимальная конечная температура сжатия (автоматическое защит‐ ное отключение) [°C]

Максимальная высота над уровнем моря в ме‐ сте установки* [м]

Допустимая окружаю‐ щая температура [°C]

Температура охлаждаю‐ щего воздуха [°C]

Температура всасывае‐ мого воздуха [°C]

* Установка в более высоких местах возможна только по согласованию с изготовителем Таб. 7

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Максимальная относительная влажность всасываемого воздуха T H

Температура всасываемого воздуха [°C] Максимальная относительная влажность всасываемого воздуха [%]

Вентиляция Указанные значения являются нормативными значениями, которые не допускается зани‐ жать. CSDX 140

Проем приточной вен‐ тиляции Z см. рисунок 14, [м2]

Вытяжной вентилятор для принудительной вентиляции: объемный поток [м3/ч] при 100 Па

Давление Максимальное избыточное рабочее давление: см. фирменную табличку Давление срабатывания предохранительного клапана при 50 Гц [бар]: Максимальное избыточ‐ ное рабочее давление [бар]

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Максимальное избыточ‐ ное рабочее давление [бар]

Давление срабатывания предохранительного клапана (50Гц) Давление срабатывания предохранительного клапана при 60 Гц [бар]: Максимальное избыточ‐ ное рабочее давление [бар]

Давление срабатывания предохранительного клапана (60Гц)

Производительность Производительность [м3/мин] при частоте сети 50 Гц: Максимальное избыточ‐ ное рабочее давление [бар]

Производительность (50 Гц) Производительность [м3/мин] при частоте сети 60 Гц: Максимальное избыточ‐ ное рабочее давление [бар]

Рекомендуемые охлаждающие масла Марка залитого охлаждающего масла указана на резервуаре маслоотделителя рядом с за‐ ливным патрубком. Информацию, необходимую для заказа охлаждающего масла, Вы найдете в разделе 11.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Рекомендуемые охлаждающие масла

Охлаждающие масла общего назначения SIGMA FLUID MOL

Без содержания силикона, синтетическое масло

Стандартное масло для всех областей применения за исклю‐ чением пищевой про‐ мышленности.

Стандартное масло для всех областей применения за ис‐ ключением пищевой промы‐ шленности.

Стандартное масло для стран Восточной и Юго-Восточной Азии, возможно ис‐ пользование во всех областях за исключе‐ нием пищевой промы‐ шленности.

Особенно подходит для машин с низкой нагрузкой.

Не разрешается использо‐ вать в странах Восточной и Юго-Восточной Азии.

Особенно подходит для машин с высокой нагрузкой.

Разрешение на примене‐ ние

40/40/0/10 мин (D 1401; ASTM-тест)

Способность к — деэмульгиро‐ ванию при 54 °C Таб. 13

Особенно подходит для ма‐ шин с высокой нагрузкой.

Рекомендуемые охлаждающие масла Охлаждающие масла для пищевой промышленности SIGMA FLUID Описание

Область примене‐ Специально для машин используе‐ ния мых в областях, где сжатый воздух может соприкасаться с продуктами питания.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Специально для машин используе‐ мых в областях, где сжатый воздух может соприкасаться с продуктами питания.

Винтовой компрессор 9_9519 02 R

Рекомендуемые охлаждающие масла

USDA H–1, NSF Разрешено при производстве упа‐ ковки для пищевых продуктов, в мясо- и птицеперерабатывающей промышленности и других отраслях по переработке продуктов питания.

USDA H–1, NSF Разрешено при производстве упа‐ ковки для пищевых продуктов, в мясо- и птицеперерабатывающей промышленности и других отраслях по переработке продуктов питания.

Способность к деэмульгирова‐ нию при 54 °C

Рекомендуемые охлаждающие масла (для пищевой промышленности) Охлаждающие масла для эксплуатации со снежными пушками SIGMA FLUID PANOLIN HLP SYNTH 46 Описание

Насыщенный сложный эфир с присадками (без содержа‐ ния нефти) Согласно критерий OECD способно к биологическому раз‐ ложению

Специально для машин, предусмотренных для эксплуата‐ ции со снежными пушками.

Способность к деэмульгирова‐ нию при 54 °C

Рекомендуемые охлаждающие масла (машины для снежных пушек)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Количество заливаемого охлаждающего масла

Количество заливаемого охлаждающего масла Заливаемое количество варьируется в зависимости от опции системы рекуперации тепла. Для машин с опцией W1, W2 или W3 необходимо долить дополнительное количество охла‐ ждающего масла для системы рекуперации тепла.

Воздушное охлаждение CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 16 Опция K2

Количество заливаемого охлаждающего масла (опция K1) Водяное охлаждение (пластинчатый теплообменник) CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 17 Опция K9

Количество заливаемого охлаждающего масла (опция K2) Водяное охлаждение (трубчатый теплообменник) CSDX 140

Количество доливаемо‐ го масла [л] (минимум – максимум)

* с учетом масла, заливаемого в систему рекуперации тепла Таб. 18

Количество заливаемого охлаждающего масла (опция K9)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Система рекуперации тепла Количество доливаемого масла увеличивается на объем охлаждающего масла в теплооб‐ меннике и трубопроводах: CSDX 140

Дополнительное коли‐ чество заливаемого ма‐ сла [л]* * Укажите количество масла, заливаемого в Вашу систему рекуперации тепла Таб. 19

Количество заливаемого охлаждающего масла (опция W1)

Опция W2 Дополнительное коли‐ чество заливаемого ма‐ сла [л] Таб. 20

Количество заливаемого охлаждающего масла (опция W2)

Опция W3 Дополнительное коли‐ чество заливаемого ма‐ сла [л]

Количество заливаемого охлаждающего масла (опция W3)

Двигатель компрессора Частота сети: 50 Гц CSDX 140

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Номинальная мощ‐ ность [кВт]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 22

Двигатель компрессора (50Гц)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Частота сети: 1000 м CSDX 140

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Номинальная мощ‐ ность [кВт]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 23

Двигатель компрессора (60Гц)

Опция K1 Двигатель вентилятора CSDX 140

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

Срок смазки подшипни‐ ков двигателя [ч]

Количество консистент‐ ной смазки в подшипни‐ ке [г]* ч = рабочие часы * Данные, указанные на фирменной табличке двигателя внесите в таблицу. Таб. 24

Двигатель вентилятора (опция K1)

Опция K2/K9 Двигатель вентилятора Частота сети: 50 Гц

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Двигатель вентилятора (опция K2/K9; 50Гц) Частота сети: 1000 м CSDX 140

Номинальная мощ‐ ность [кВт]

Номинальная частота вращения [мин-1]

Двигатель вентилятора (опция K2/K9; 60Гц)

Звуковое излучение [дБ(А)] Частота сети

Уровень звукового давления согласно ISO 2151 и основополагающего стандарта ISO 9614-2, допустимая погрешность: ± 3 дБ(A) при максимальном избыточном рабочем да‐ влении * Опция K2/K9 Таб. 27

Электрическое питание Основные требования Машина сконструирована в соответствии условий электроснабжения согласно стандарта EN 60204-1 (IEC 60204-1), раздела 4.3. Если потребителем не установлены иные условия, необходимо соблюдать предельные зна‐ чения, описанные в данном стандарте. Кроме того, рекомендуем провести согласование между потребителем и поставщиком на ос‐ нове стандарта EN 60204-1, приложение B. Для электрического подключения машины необходима симметричная трехфазная сеть. В симметричной трехфазной сети напряжение и сдвиг фаз между отдельными фазами оди‐ наковы. Эксплуатация машины допускается только от трехфазной сети с системой заземления типа TN или TT. Не допускается подключение к сети с системой заземления типа IT без дополнительных ме‐ роприятий (контроля сопротивления изоляции и т.д.). Машина рассчитана для эксплуатации от сети электроснабжения внутри промышленных объектов, отделенной от общественной сети электроснабжения с помощью трансформатора или генератора. Кабель питания внутри шкафа должен быть проложен кратчайшим путем.

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Характеристики электрического подключения

При необходимости подключения к машине внешних сенсоров или коммуникационных кабе‐ лей, использовать для этого экранированные кабели и кабельные вводы, отвечающие тре‐ бованиям ЭМС. Дополнительные требования Требования к трехфазной сети для машины, оснащенных: ■

с холодоосушителем с электропитанием через трансформатор

Подключение данной машины допускается только к трехфазной сети с системой заземления типа TN или TT с заземленной нулевой точкой при соединении «звездой». Не допускается подключение данной машины к трехфазной сети с заземленной фазой, так как это может привести к опасному перенапряжению. Не допускается подключение к сети с системой заземления типа IT без дополнительных ме‐ роприятий (контроля сопротивления изоляции, специального исполнения частотного преоб‐ разователя и т.д.). Дополнительная информация

На электрической схеме в разделе 13.4 указаны дополнительные сведения относительно электрического подключения.

Характеристики электрического подключения Нижеследующие сечения кабелей питания (медный многожильный кабель) и предохраните‐ ли (плавкий предохранитель, класс эксплуатации gL) рассчитаны согласно стандарта DIN VDE 0100-430 (IEC 60364-4-43 и IEC 60364-4-473) и DIN VDE 0298-4 для окружающей температуры 30 °C и способа прокладки C. ➤ При других условиях эксплуатации проверить сечение кабелей питания и привести в соответствие. К другим условиям эксплуатации относятся, например:

Частота сети: 50 Гц Номинальное напряжение: 200В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 200В/3/50Гц

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Характеристики электрического подключения

Номинальное напряжение: 230В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 230В/3/50Гц Номинальное напряжение: 400В±10%/3/50Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 400В/3/50Гц

Частота сети: 1000 м Номинальное напряжение: 230В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц Номинальное напряжение: 380В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Номинальное напряжение: 440В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц Номинальное напряжение: 460В±10%/3/60Гц CSDX 140

Предохранитель на вво‐ де [A]

Характеристики подключения 460В/3/60Гц

Опция K2/K9 Водяное охлаждение При возникновении утечки, охлаждающее масло может попасть в охлаждающую воду. ➤ Нагрев питьевой воды производить только посредством соответствующего теп‐ лообменника. При добавлении в охлаждающую воду средства против замерзания, изменяется удель‐ ная теплопроводность охлаждающей воды и необходимый объем потока. ➤ Для обеспечения безупречной работы системы охлаждения, обратитесь в автори‐ зованную сервисную службу KAESER. ➤ Для предотвращения сбоев в работе вследствие образование ржавчины, отложе‐ ний извести и загрязнении необходимо соблюдать указанные требования к охлаж‐ дающей воде Обязательным условием является проведение мероприятий по фильтрации и подго‐ товке охлаждающей воды. Адреса организаций, выполняющих анализ качества воды и поставляющих приборы для подготовки воды Вы можете получить, обратившись в фирму KAESER. Возможны следующие конструктивные варианты:

Опция К2: водяное охлаждение с пластинчатым теплообменником, раздел 2.15.1

Опция K9: водяное охлаждение с трубчатым теплообменником, раздел 2.15.2

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Винтовой компрессор 9_9519 02 R

Открытая система охлаждения Примером открытой системы охлаждения может служить охлаждающий контур с открытой градирней, где охлаждающая вода остывает за счет испарения. Поскольку часть воды ис‐ паряется, она должна постоянно добавляться. Последствием испарения является концен‐ трация загрязняющих веществ в охлаждающей воде, загрязнение может усугубляться вследствие контакта воды с окружающим воздухом. При доливке охлаждающей воды сле‐ дует соблюдать требования, предъявляемые к охлаждающей воде. Закрытая система охлаждения В закрытой системе охлаждения охлаждающая вода не контактирует с атмосферным возду‐ хом. Поэтому исключены попадание загрязнений из воздуха и обогащение кислородом. Проточная система охлаждения Проточная система охлаждения это открытая система охлаждения. Водопроводная вода, во‐ да из подземных источников и открытых водоемов проходит через систему охлаждения один раз. Дополнительная информация

Направление потока, размеры и расположение соединительного штуцера Вы найдете на га‐ баритном чертеже в разделе 13.3.

Опция K2 Водяное охлаждение (пластинчатый теплообменник) Первичный контур теплообменника подключен к машине. Приведенные данные отно‐ сятся к вторичному контуру теплообменника.

Технические данные Повышение температуры охлаждающей воды на 10 K:

Максимально допусти‐ мая температура на входе [°C]

Температура охлаждающей воды (ΔT=10K) Повышение температуры охлаждающей воды на 30 K:

Максимально допусти‐ мая температура на входе [°C]

Температура охлаждающей воды (ΔT=30K)

Инструкция по эксплуатации CSDX T SIGMA CONTROL 2

Спецификация теплообменника: CSDX 140

Максимальное избыточ‐ ное рабочее давление [бар]

Максимально допусти‐ мая температура на вы‐ ходе [°C]

Максимальный объем‐ ный поток [м3/ч]

Непригодные охла‐ ждающие средства

Соленая вода Использование водных растворов разрешено только по согласова‐ нию с фирмой KAESER

Спецификация: Теплообменник (опция K2)

Качество охлаждающей воды Свойства/содержащиеся вещества

Источник