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KAESER CSD 75 Service Manual

Manual is about: Screw Compressor

Summary of CSD 75

  • Page 1

    Service manual use screw compressor model: csd 75 gl---nr.: 100265_00060---00 01 l volt l cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . L wye---delta start l 115 v receptacle l d.O.L. Start l outdoor modification l psig l rainhoods . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 3: Table Of Contents

    Table of contents chapter --- page i 1 technical specification 1 --- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 compressor unit 1 --- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 noise lev...

  • Page 4: Table Of Contents

    Table of contents chapter --- page ii 7 putting into operation 7 --- 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 points to be observed before putting into operation 7 --- 22 . . . . . . . . . . . . . . . . . . . . . . 7.2 points to be observed before st...

  • Page 5: Table Of Contents

    Table of contents chapter --- page iii 11 appendix 11 --- 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 wiring diagram 11 --- 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 6: Technical Specification

    Technical specification 1 --- 1 1 technical specification 1.1 compressor unit model csd 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum gauge working pressure 125 psig . . . . . . . . . . . . . . . . . . . . Minimum gauge working pressure 80 psig . . . ...

  • Page 7: Technical Specification

    Technical specification 1 --- 2 1.5 set point of the safety relief valve 80---125 psig compressor unit --- activating pressure 155 psig . . . . 1.6 installation requirements max. Height above sea level of the place of installation 3000 ft. . . (for all heights above please contact authorized kaeser ...

  • Page 8: Technical Specification

    Technical specification 1 --- 3 1.8 oil recommendations lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in compressor oils. These deposits block the flow of lubricant and cause excessive wear and failure of moving parts. Contamination of the oil can a...

  • Page 9: Technical Specification

    Technical specification 1 --- 4 21 cfr §178.3570 and is usda h---1 approved. Fg---460 is approved for canning, food packing, meat and poultry processing and other applications where incidental food contact may occur. Specialty kaeser lubricants (refer to product information to determine suitability....

  • Page 10: Technical Specification

    Technical specification 1 --- 5 acceptable not recommended viton high nitrile buna n teflon epoxy paint oil resistant alkyd nylon delrin celcon neoprene sbr rubber low nitrile buna n acrylic paint lacquer polystyrene pvc abs polycarbonate bowls can be etched by any synthetic lubricant. We recommend ...

  • Page 11: Technical Specification

    Technical specification 1 --- 6.

  • Page 12: Safety

    Safety 2 --- 7 2 safety regulations read this service manual carefully and observe cautionary references before putting this compressor package into operation and before carrying out any maintenance. 2.1 explanation of symbols and references this symbol is placed before all references to safety wher...

  • Page 13: Safety

    Safety 2 --- 8 any alterations or reconstruction carried out without the prior written authorization of kaeser compressors inc. Will invalidate the war- ranty. Do not weld on or near any pressurized components (e.G., pipes, tanks, fittings) or make any modifications that require heat treatment. - do...

  • Page 14: Safety

    Safety 2 --- 9 2.6 environmental protection condensate drainage the condensate accumulating during compression must be fed via a suitable drainage system, collected in special canisters and disposed of according to environmental regulations. Maintenance materials/wear items/replacement parts ensure ...

  • Page 15: General

    General 3 --- 10 3 general the service manual must always be available for use at the location of the compressor package. 3.1 proper use of the compressor the compressor package is intended solely for the purpose of generating compressed air. Any further use outside of this purpose is considered imp...

  • Page 16: Transport

    Transport 4 --- 11 4 transport 4.1 transport instructions we recommend a fork lift truck or lifting equipment for transporting the compressor pack- age to avoid damage to the cabinet and framework. Min. 63” min. 35” measurements in inches spreader bar do not exert any side forces on the compressor p...

  • Page 17: Construction And Operation

    Construction and operation 5 --- 12 5 construction and operation 5.1 principle of compression the stationary compressor package is fitted with a single stage, oil---injected airend. The two rotors, the driven male rotor and the female rotor, both mounted in antifriction bear- ings, are fitted into t...

  • Page 18: Construction And Operation

    Construction and operation 5 --- 13 5.3 identification of the components position details in ( ) correspond with the pipe and instrument flow diagram (p & i diagram) 5 2 6 3 8 7 1 4 9 1 inlet valve (2) 6 control cabinet 2 coupling (53) 7 oil separator tank 3 drive motor (3) 8 air filter (1) 4 oil fi...

  • Page 19: Construction And Operation

    Construction and operation 5 --- 14.

  • Page 20: Construction And Operation

    Construction and operation 5 --- 15.

  • Page 21: Construction And Operation

    Construction and operation 5 --- 16 5.5 dual control p max p min full load standstill mo to r p o w e r p re ssu re time t1 t2 1 2 3 4 5 idle in dual control (combined idle and start ---stop) the compressor normally runs at full -- load, idle or standstill. The controller regulates the compressor pa...

  • Page 22: Construction And Operation

    Construction and operation 5 --- 17 5.6 quadro control 1 full load standstill mo to r p o w e r p re ssu re p max p min t p rise t p decay running period idle/ standstill period run ---on period 1 1 1 1 time stop point for the running period or idle / standstill period 1 3 2 2 4 p max upper switchin...

  • Page 23: Construction And Operation

    Construction and operation 5 --- 18 - if the air systems pressure rises to the upper switching point and the running period has already expired, the compressor package is switched off after the run ---on period has expired (2). - if the air systems pressure rises to the upper switching point before ...

  • Page 24: Installation

    Installation 6 --- 19 6 installation 6.1 installation requirements the compressor should be mounted on level surface. For any special application please consult with the manufacturer. Safe operation of the compressor package is only ensured if the ambient temperature re- mains within the limits stat...

  • Page 25: Installation

    Installation 6 --- 20 solution b: exhaust air used for space heating the hot air is forced through a conduit (see chapter 1.6) into the room to be heated. Consult the manufacturer with regard to length of conduit and for maximum allowable pressure drop for this compressor package. Safe operation of ...

  • Page 26: Installation

    Installation 6 --- 21 1.25 x fla (see chapter 1.4) wire temperature rating correction factor for 40 c 100a 60 c 0.82 > 100a 75 c 0.88.

  • Page 27: Initial Start

    Initial start 7 --- 22 7 putting into operation 7.1 points to be observed before putting into operation every compressor package is given a test run at the factory and carefully inspected before shipment. The test run confirms that the package conforms to the specification data and runs perfectly. H...

  • Page 28: Initial Start

    Initial start 7 --- 23 - during installation of the compressor unit, ensure that a distance of at least 40 ” is kept between the air intake of the unit and any wall. Check the oil level in the oil separator tank (see chapter 9.11). - check that the airend rotates in the correct direction (see chapte...

  • Page 29: Initial Start

    Initial start 7 --- 24 7.3 checklist is the floor at the place of installation solid and level? Yes no is the space large enough for the compressor package or its components? Yes no are inlet and exhaust air apertures available in sufficient size and number? Yes no are all components of the compress...

  • Page 30: Initial Start

    Initial start 7 --- 25 7.4 direction of rotation check the compressor is wired for connection to a clockwise phase se- quence power supply. A check of the direction of rotation can be made by testing the phase sequence. Arrows showing the direction of rotation are located on the motor and on the air...

  • Page 31: Initial Start

    Initial start 7 --- 26 7.6 motor overload protection switch adjustment before any adjustments are carried out to the compressor package, lock the main disconnect in the ”off” position in accordance with appli- cable lock out/tag out procedures (example: osha cfr 29 § 1910.147) to ensure the compress...

  • Page 32: Initial Start

    Initial start 7 --- 27 7.8 measures to be taken before initial start follow the procedure detailed bellow before initial start, after an oil change or if the com- pressor has not been operated for a period of three months or longer before starting the compressor: 7.8.1 pour a small quantity of oil i...

  • Page 33: Operation

    Operation 8 --- 28 8 operation 8.1 control panel 1 2 1 sigma control 2 emergency stop pushbutton 8.2 sigma controller the sigma controller (1) is fitted in the control cabinet in the compressor package and serves as the control panel. It has 11 keys and 9 leds. Operation of the compressor pack- age ...

  • Page 34: Operation

    Operation 8 --- 29 8.3.1 function keys 1 2 8 9 4 3 11 10 5 7 6 1 on key (“i”) 6 menu scroll --- down key 2 off key (“0”) 7 menu scroll --- up key 3 timer on/off key 8 escape key 4 remote on key 9 return key 5 load/idle key 10 info --- event key 11 acknowledge (reset) key 8.3.2 light emitting diodes ...

  • Page 35: Operation

    Operation 8 --- 30 8.4 starting and stopping the compressor unit do not start and stop the compressor package with the main discon- nect switch. The compressor must always be switched on and off with keys (1) and (2). To turn the compressor on (local): switch on the main disconnect switch. The contr...

  • Page 36: Operation

    Operation 8 --- 31 8.6 acknowledgement of service messages when maintenance is due the yellow led (15) on sigma control flashes. Before any maintenance is due an initial warning is displayed to allow coordination of service and maintenance personnel and provision of necessary servicing materials. (l...

  • Page 37: Maintenance

    Maintenance 9 --- 32 9 maintenance 9.1 observe the following rules during all maintenance and servicing work: work on power driven equipment may only be carried out by trained or specialized personnel. Follow all applicable osha and local safety regulations. If a power failure occurs, the compressor...

  • Page 38: Maintenance

    Maintenance 9 --- 33 9.2 location of maintenance doors and cover panels 1 --- co n tr o l c a b in e t d o o r 2 --- 5 c o v e r p a n e ls 31 2 45.

  • Page 39: Maintenance

    Maintenance 9 --- 34 9.3 regular maintenance (compressor) interval work to be done see chapter 50 h after initial start check all electrical connections for tightness and toghten if necessary weekly check the oil level 9.11 check the filter mats for contamination 9.5 indication by sigma control clea...

  • Page 40: Maintenance

    Maintenance 9 --- 35 9.4 cleaning the oil cooler and aftercooler the oil and air aftercooler must be checked for clogging regularly. Heavy contamination could lead to excessive high temperatures in the oil circulation system. See regular maintenance schedule for cooler maintenance interval (chapter ...

  • Page 41: Maintenance

    Maintenance 9 --- 36 9.5 cleaning or replacing the filter mat clean the filter mat every week depending on the dust content of the intake air and replace if necessary as detailed in the maintenance schedule (see chapter 9.3). Switch off the compressor package (see chapter 8.4). Lock the main disconn...

  • Page 42: Maintenance

    Maintenance 9 --- 37 remove cover panel (3, siee chapter 9.2). To open the air filter housing: open the snap fasteners (1) on the dust collector (3) and remove the dust collector (3) with the insert. Take the insert out of the dust collector (3). Pull out the air filter cartridge (4) by turning slig...

  • Page 43: Maintenance

    Maintenance 9 --- 38 9.7 maintaining the electric motor compressor motor: the bearings are greased via fittings on the tops of the bearing end shields. Initial greasing of the bearings is carried out by the manufacturer. See chapter 1.9 for greasing periods, quantity and approved greases. Remove cov...

  • Page 44: Maintenance

    Maintenance 9 --- 39 9.9 venting the compressor unit switch off the compressor unit (see chapter 8.4). Lock the main disconnect in the ”off” position in accordance with ap- plicable lock out/tag out procedures to ensure the compressor does not restart. Lock the isolation shut-- off valve in the ”clo...

  • Page 45: Maintenance

    Maintenance 9 --- 40 oil mist can escape when the oil separator tank is vented. When inserting the maintenance hose into the compressor’s hose couplings, always have the ball valve closed and the hose end se- cured before slowly opening the ball valve. Beware of air/oil mist that could blow out of t...

  • Page 46: Maintenance

    Maintenance 9 --- 41 remove cover panel (2, siee chapter 9.2). 1 2 1 oil filter cartridge 2 turn in this direction to unscrew the cartridge twist the used or contaminated oil filter cartridge counter clockwise to remove and catch escaping oil in a suitable container. Dispose of the old oil filter an...

  • Page 47: Maintenance

    Maintenance 9 --- 42 9.11 topping off the oil the oil level indicator (9) of machines in operation should be checked weekly. The machine should be topped off with oil as soon as the minimum level (1) (border of green and red) is reached. The machine may only be operated when the oil level indicator ...

  • Page 48: Maintenance

    Maintenance 9 --- 43 1 2 3 4 9 11 12 10 5 b a lo w hi g h a b c 8 7 6 1 ball valve 4 filler plug 8 maintenance hose (6 ---8) a shut (oil top --- off) 9 oil level indicator b open 5 oil separator tank 10 hose coupling 2 pressure gauge 6 nozzle 11 ball valve (oil drain) 3 hose coupling 7 ball valve 12...

  • Page 49: Maintenance

    Maintenance 9 --- 44 always use the same brand and type of oil when topping off the oil. (see label on the oil separator tank). During an oil change, drain the old oil completely and always replace the oil filter. Never mix different oil types or brands. Oil recommendations see chapter 1.8 9.12 oil ...

  • Page 50: Maintenance

    Maintenance 9 --- 45 1 2 3 4 9 11 12 10 5 b a lo w hi g h a b c 8 7 6 1 ball valve 4 filler plug 8 maintenance hose (6 ---8) a shut (oil top --- off) 9 oil level indicator b open 5 oil separator tank 10 hose coupling 2 pressure gauge 6 nozzle 11 ball valve (oil drain) 3 hose coupling 7 ball valve 12...

  • Page 51: Maintenance

    Maintenance 9 --- 46 hang the maintenance hose into the container and secure. Open the oil drain valve (11). Slowly open the ball valve (7). The remaining pressure in the oil circulation forces out the oil. When air escapes, close the ball valve (7) immediately. Close the oil drain valve (11). Disco...

  • Page 52: Maintenance

    Maintenance 9 --- 47 9.12.3 draining the oil using own compressed air shut down the compressor unit under full load (see chapter 8.4). Lock the main disconnect in the ”off” position in accordance with ap- plicable lock out/tag out procedures to ensure the compressor does not restart. Lock the isolat...

  • Page 53: Maintenance

    Maintenance 9 --- 48 perform a test run when the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.4) and lock the main disconnect in the ”off” position in accordance with applicable lock out/ tag out procedures (example: osha cfr 29 § 1910.147) to e...

  • Page 54: Maintenance

    Maintenance 9 --- 49 20 20 20 20 14 17 19 25 15 16 21 21 23 14 cover 16 air pipe 20 union nut 15 dirt trap 17 hexagonal screw 21 gasket (with copper pipe) 19 self ---locking nut 23 oil separator cartridge 25 minimum pressure/check valve remove cover panel (3, siee chapter 9.2). Loosen the union nuts...

  • Page 55: Maintenance

    Maintenance 9 --- 50 perform a test run when the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.4) and lock the main disconnect in the ”off” position in accordance with applicable lock out/ tag out procedures (example: osha cfr 29 § 1910.147) to e...

  • Page 56: Maintenance

    Maintenance 9 --- 51 9.14 maintenance schedule model no. Serial no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date description of work operating hours signature.

  • Page 57

    Spare parts and after sales service 10 --- 52 10 spare parts and after sales service 10.1 service parts and maintenance parts description qty. Order no. Oil filter 1 6.3464.0 air filter cartridge 1 6.3564.0 filter mat 1 6.3572.0 oil separator cartridge complete set comprising: separator cartridge ga...

  • Page 58: Appendix

    Appendix 11 --- 53 11 appendix 11.1 wiring diagram.

  • Page 77: Appendix

    Appendix 11 --- 72 11.2 maintenance schedule model no. Serial no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date description of work operating hours signature.

  • Page 78: Appendix

    Appendix 11 --- 73 11.3 trouble shooting: possible cause ---remedy do not attempt to carry out any repair until you are certain of its cause. 11.3.1 airend temperature is too high (greater than 167 f-- 200 f) possible cause: remedy: cooling air inlet or outlet is too close to wall or other blockage....

  • Page 79: Appendix

    Appendix 11 --- 74 possible cause: remedy: motor is running two phase: defective motor or blown fuse. Check input power, check wiring, tigh- ten any loose connections. Replace fuse(s) or motor if necessary. Oil separator cartridge is contamina- ted. Check pressure differential across car- tridge. Re...

  • Page 80: Appendix

    Appendix 11 --- 75 11.3.4 oil leaks out of air filter possible cause: remedy: oil level in separator tank is too high. Drain oil to correct level. Inlet valve faulty. Find the fault and replace the defective part. 11.3.5 full -- load/idle sequence occurs too frequently (short cycles) possible cause:...

  • Page 81: Appendix

    Appendix 11 --- 76 11.3.8 excessive oil consumption possible cause: remedy: wrong oil is being used in the unit. Replace with correct oil type. Consult authorized kaeser distributor for other oil types not listed. Oil separator cartridge has ruptured. Check pressure differential and re- place oil se...