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Operator Manual Rotary screw compressor CSD 100/125 T 901726 08 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
Original instructions /KKW/SCSDX 2.18 en Z1 SBA-SCHRAUBEN-T-SC /KKW/SSC 2.08 Z1 20180111 113017
Contents
901726 08 USE
1
Regarding this Document 1.1 Using this document ......................................................................................................... 1.2 Further documents ........................................................................................................... 1.3 Copyright .......................................................................................................................... 1.4 Symbols and labels .......................................................................................................... 1.4.1 Warnings ............................................................................................................. 1.4.2 Potential damage warnings ................................................................................ 1.4.3 Other alerts and their symbols ............................................................................
1 1 1 1 1 2 2
2
Technical Data 2.1 Nameplate ........................................................................................................................ 2.2 Options ............................................................................................................................. 2.3 Weight .............................................................................................................................. 2.4 Temperature ..................................................................................................................... 2.5 Ambient conditions ........................................................................................................... 2.6 Ventilation ........................................................................................................................ 2.7 Pressure ........................................................................................................................... 2.8 Free air delivery (FAD) ..................................................................................................... 2.9 Cooling Oil Recommendation .......................................................................................... 2.9.1 Basic Information ................................................................................................ 2.9.2 KAESER Lubricants ............................................................................................ 2.10 Cooling oil charge ............................................................................................................ 2.11 Motors and power ............................................................................................................ 2.11.1 Compressor drive motor ..................................................................................... 2.11.2 Fan motor ........................................................................................................... 2.11.3 Fan motor ........................................................................................................... 2.12 Noise emission ................................................................................................................. 2.13 Power Supply ................................................................................................................... 2.14 Power supply specifications ............................................................................................. 2.15 Water-cooling ................................................................................................................... 2.15.1 Water cooling (plate-type heat exchanger) ......................................................... 2.15.2 Water cooling (Bundled pipe heat exchanger) ................................................... 2.16 Heat recovery ................................................................................................................... 2.17 Refrigerated dryer ............................................................................................................
4 4 5 5 6 6 6 7 7 7 7 8 9 9 9 10 10 10 11 12 13 15 17 20
3
Safety and Responsibility 3.1 Basic instructions ............................................................................................................. 3.2 Specified use .................................................................................................................... 3.3 Improper use .................................................................................................................... 3.4 User's Responsibilities ..................................................................................................... 3.4.1 Observe statutory and universally accepted regulations .................................... 3.4.2 Qualified personnel ............................................................................................. 3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 3.5 Dangers ............................................................................................................................ 3.5.1 Safely dealing with sources of danger ................................................................ 3.5.2 Safe machine operation ...................................................................................... 3.5.3 Organizational Measures .................................................................................... 3.5.4 Danger Areas ...................................................................................................... 3.6 Safety devices .................................................................................................................. 3.7 Working life of safety functions ........................................................................................ 3.8 Safety signs ...................................................................................................................... 3.9 Emergency situations ....................................................................................................... 3.9.1 Correct fire fighting ............................................................................................. 3.9.2 Treating injuries from handling cooling oil .......................................................... 3.9.3 Injury from Handling Refrigerant .........................................................................
21 21 21 21 21 22 22 22 23 25 27 27 27 28 28 31 31 31 32
Operator Manual CSD 100/125 T
Rotary screw compressor
i
Contents
ii
3.10 Warranty ........................................................................................................................... 3.11 Environmental protection .................................................................................................
33 33
4
Design and Function 4.1 Enclosure ......................................................................................................................... 4.2 Machine function .............................................................................................................. 4.2.1 Refrigerated dryer ............................................................................................... 4.2.2 Safety devices .................................................................................................... 4.2.3 Floating relay contacts ........................................................................................ 4.3 Operating panel SIGMA CONTROL 2 ............................................................................. 4.4 Operating modes and control modes ............................................................................... 4.4.1 Operating modes ................................................................................................ 4.4.2 Control modes .................................................................................................... 4.5 Refrigerated Dryer Control Modes ................................................................................... 4.6 Options ............................................................................................................................. 4.6.1 Controller SIGMA CONTROL 2: Connection to control technology .................... 4.6.2 Machine mountings ............................................................................................. 4.6.3 Water cooling ...................................................................................................... 4.6.4 Cooling air filter mat ............................................................................................ 4.6.5 Heat recovery .....................................................................................................
34 34 36 36 36 37 39 39 40 42 42 42 42 43 44 44
5
Installation and Operating Conditions 5.1 Ensuring safety ................................................................................................................ 5.2 Installation conditions ....................................................................................................... 5.2.1 Determining location and clearances .................................................................. 5.2.2 Ensuring adequate ventilation ............................................................................ 5.2.3 Exhaust duct design ........................................................................................... 5.3 Operating the machine in a compressed air network .......................................................
46 46 46 47 48 48
6
Installation 6.1 Ensuring safety ................................................................................................................ 6.2 Reporting Transport Damage ........................................................................................... 6.3 Connecting the machine with the compressed air network .............................................. 6.4 Connecting the condensate drain .................................................................................... 6.5 Connecting the external pressure transducer .................................................................. 6.6 Refrigerated dryer: Connecting the transformer according to the power supply. ............. 6.7 Connecting the machine with the power supply ............................................................... 6.8 Options ............................................................................................................................. 6.8.1 Anchoring the machine ....................................................................................... 6.8.2 Connecting the water cooling ............................................................................. 6.8.3 Connecting the heat recovery system ................................................................
49 50 50 50 52 53 53 54 54 54 55
7
Initial Start-up 7.1 Ensuring safety ................................................................................................................ 7.2 Instructions to be observed before commissioning or re-commissioning ......................... 7.3 Checking installation and operating conditions ................................................................ 7.4 Setting the overload protection relay ................................................................................ 7.5 Setting the motor overload protection relay ..................................................................... 7.6 Filling cooling oil into the airend ....................................................................................... 7.7 Activating and deactivating the MODULATING control .................................................... 7.8 Starting the machine for the first time .............................................................................. 7.9 Setting the setpoint pressure ........................................................................................... 7.10 Setting the display language ............................................................................................
57 58 58 59 59 59 61 61 62 62
8
Operation 8.1 Switching on and off ......................................................................................................... 8.1.1 Switching on .......................................................................................................
64 64
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
Contents
8.1.2 Switching off ....................................................................................................... Switching off in an emergency and switching on again .................................................... Switching on and off from a remote control center ........................................................... Using the timer for switching on and off ........................................................................... Interpreting operation messages ...................................................................................... Acknowledging alarm and warning messages .................................................................
64 65 65 66 67 67
Fault Recognition and Rectification 9.1 Basic instructions ............................................................................................................. 9.2 Other faults .......................................................................................................................
69 69
8.2 8.3 8.4 8.5 8.6 9
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10
Maintenance 10.1 Ensuring safety ................................................................................................................ 71 10.2 Following the maintenance plan ....................................................................................... 72 10.2.1 Logging maintenance work ................................................................................. 72 10.2.2 Resetting maintenance interval counters ............................................................ 72 10.2.3 Regular maintenance tasks ................................................................................ 72 10.2.4 Cooling oil changing interval ............................................................................... 74 10.2.5 Regular service tasks ......................................................................................... 74 10.3 Control cabinet: Clean or renew the filter mat .................................................................. 75 10.4 Cooler maintenance ......................................................................................................... 75 10.5 Water-cooling Maintenance ............................................................................................. 76 10.6 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 77 10.7 Maintaining the heat recovery system .............................................................................. 78 10.8 Air filter maintenance ....................................................................................................... 78 10.8.1 Cleaning the pre-filter ......................................................................................... 79 10.8.2 Cleaning or replacing the pre-filter and air filter cartridge ................................... 79 10.9 Motor maintenance .......................................................................................................... 80 10.10 Checking the Coupling ..................................................................................................... 81 10.11 Testing the safety relief valve ........................................................................................... 82 10.12 Checking the overheating safety shutdown function ........................................................ 83 10.13 Testing the EMERGENCY STOP push button ................................................................. 84 10.14 Checking the cooling oil level ........................................................................................... 84 10.15 Venting the machine (de-pressurizing) ............................................................................ 85 10.16 Replenishing the cooling oil ............................................................................................. 87 10.16.1 Venting the machine (de-pressurizing) ............................................................... 87 10.16.2 Topping off with cooling oil and trial run ............................................................. 88 10.17 Changing the cooling oil ................................................................................................... 89 10.18 Changing the oil filter element .......................................................................................... 94 10.19 Changing the oil separator cartridge ................................................................................ 95 10.20 Cleaning the refrigerant condenser .................................................................................. 97 10.21 Maintaining the condensate drain .................................................................................... 97 10.21.1 Condensate drain check ..................................................................................... 97 10.21.2 Changing the service unit ................................................................................... 98 10.22 Documenting maintenance and service work .................................................................. 102
11
Spares, Operating Materials, Service 11.1 Note the nameplate .......................................................................................................... 11.2 Ordering spare parts and operating fluids/materials ........................................................ 11.3 KAESER AIR SERVICE ................................................................................................... 11.4 Replacement parts for service and repair ........................................................................
12
Decommissioning, Storage and Transport 12.1 Decommissioning ............................................................................................................. 111 12.1.1 Temporary decommissioning .............................................................................. 111 12.1.2 Long-term decommissioning ............................................................................... 111
Operator Manual CSD 100/125 T
Rotary screw compressor
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iii
Contents
12.2 Packing ............................................................................................................................ 112 12.3 Storage ............................................................................................................................. 112 12.4 Transport .......................................................................................................................... 112 12.4.1 Safety .................................................................................................................. 112 12.4.2 Transport with a forklift truck ............................................................................... 113 12.4.3 Transport with a crane ........................................................................................ 113 12.5 Disposal ........................................................................................................................... 115 12.5.1 Battery disposal .................................................................................................. 115 13
iv
Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 13.3 Dimensional drawing ........................................................................................................ 13.4 Electrical Diagram ............................................................................................................
Operator Manual CSD 100/125 T
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Rotary screw compressor 901726 08 USE
List of Illustrations
Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Fig. 32 Fig. 33 Fig. 34 Fig. 35 Fig. 36 Fig. 37 Fig. 38 Fig. 39 Fig. 40 Fig. 41 Fig. 42 Fig. 43 Fig. 44 Fig. 45 Fig. 46 Fig. 47 Fig. 48 Fig. 49 Fig. 50 Fig. 51
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Three-phase (wye system); 4 wire; center point solidly grounded ............................................. Three-phase (wye system); 3 wire; center point solidly grounded ............................................. Location of safety signs .............................................................................................................. Enclosure overview .................................................................................................................... Machine overview ....................................................................................................................... Refrigerated dryer ...................................................................................................................... Keys - overview .......................................................................................................................... Indicators – overview .................................................................................................................. RFID sensor field ........................................................................................................................ Machine mountings .................................................................................................................... Water-cooling (Option K2) .......................................................................................................... Water cooling (Option K9) .......................................................................................................... Cooling air filter mat (option K3) ................................................................................................. Function of the heat recovery ..................................................................................................... Recommended machine placement and dimensions [in.] .......................................................... Compressed air piping ............................................................................................................... Connecting the condensate drain ............................................................................................... Connecting the water cooling ..................................................................................................... Connecting the heat recovery system ........................................................................................ Inlet valve filling port ................................................................................................................... Coupling ..................................................................................................................................... MODULATING control: Setting the shut-off valve ...................................................................... Switching on and off ................................................................................................................... Switching off in an emergency ................................................................................................... Switching on and off from a remote control center ..................................................................... Using the timer for switching on and off ..................................................................................... Acknowledging messages .......................................................................................................... Switching cabinet ventilation ...................................................................................................... Clean cooler/radiator .................................................................................................................. Cooling air filter mat ................................................................................................................... Cleaning the pre-filter ................................................................................................................. Air filter maintenance .................................................................................................................. Motor maintenance ..................................................................................................................... Checking the coupling ................................................................................................................ Testing the EMERGENCY STOP push button ........................................................................... Checking the cooling oil level ..................................................................................................... Venting the machine ................................................................................................................... Replenishing the cooling oil ........................................................................................................ Changing the cooling oil, oil separator tank ............................................................................... Changing the cooling oil, oil cooler ............................................................................................. Changing the cooling oil, airend ................................................................................................. Changing the cooling oil, heat recovery system ......................................................................... Changing the oil filter element .................................................................................................... Changing the oil separator cartridge .......................................................................................... Refrigeration dryer ...................................................................................................................... Condensate drain check ............................................................................................................. Changing the service unit ........................................................................................................... Changing the service unit ........................................................................................................... Transport with a forklift truck ...................................................................................................... Transport with a crane ................................................................................................................ Battery disposal ..........................................................................................................................
Operator Manual CSD 100/125 T
Rotary screw compressor
11 11 29 34 35 36 37 38 39 43 43 43 44 45 47 50 52 54 55 60 60 61 64 65 66 67 68 75 76 77 79 80 81 82 84 85 86 87 90 91 92 93 94 96 97 98 99 100 113 114 115
v
List of Illustrations
vi
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
List of Tables
Tab. 1 Tab. 2 Tab. 3 Tab. 4 Tab. 5 Tab. 6 Tab. 7 Tab. 8 Tab. 9 Tab. 10 Tab. 11 Tab. 12 Tab. 13 Tab. 14 Tab. 15 Tab. 16 Tab. 17 Tab. 18 Tab. 19 Tab. 20 Tab. 21 Tab. 22 Tab. 23 Tab. 24 Tab. 25 Tab. 26 Tab. 27 Tab. 28 Tab. 29 Tab. 30 Tab. 31 Tab. 32 Tab. 33 Tab. 34 Tab. 35 Tab. 36 Tab. 37 Tab. 38 Tab. 39 Tab. 40 Tab. 41 Tab. 42 Tab. 43 Tab. 44 Tab. 45 Tab. 46 Tab. 47 Tab. 48 Tab. 49 Tab. 50 Tab. 51 Tab. 52 Tab. 53 Tab. 54
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Danger levels and their definition (personal injury) .................................................................... Danger levels and their definition (damage to property) ............................................................ Nameplate .................................................................................................................................. Options ....................................................................................................................................... Machine weight .......................................................................................................................... Temperature ............................................................................................................................... Ambient conditions ..................................................................................................................... Ventilation ................................................................................................................................... Safety relief valve activating pressure ....................................................................................... Free air delivery .......................................................................................................................... Cooling oil charge (Option K1) ................................................................................................... Cooling oil charge (Option K2) ................................................................................................... Cooling oil charge (Option K9) ................................................................................................... Cooling oil charge (Option W2) .................................................................................................. Cooling oil charge (Option W3) .................................................................................................. Compressor drive motor ............................................................................................................. Fan motor (Option K1) ................................................................................................................ Fan motor (Option K2/K9) .......................................................................................................... Noise emission ........................................................................................................................... Power supply details (230V / 3 / 60Hz) ...................................................................................... Power supply details (380V / 3 / 60Hz) ...................................................................................... Power supply details (460V / 3 / 60Hz) ...................................................................................... Power supply details (575V / 3 / 60Hz) ..................................................................................... Water cooling K2: Individual design data ................................................................................... Component specification (Option K2) ......................................................................................... Cooling water quality (Plate-type heat exchanger) ..................................................................... Cooling water temperature (ΔT= 20 °F) ..................................................................................... Cooling water temperature (ΔT= 50 °F) ..................................................................................... Water cooling K9: Individual design data ................................................................................... Component specification (Option K9) ......................................................................................... Cooling water quality (Bundled-pipe heat exchanger) ................................................................ Cooling water temperature (ΔT=20 °F) ...................................................................................... Cooling water temperature (ΔT=50 °F) ...................................................................................... Heat recovery: Individual design data ........................................................................................ Specification: Heat exchanger (Option W2/W3) ......................................................................... Quality of the heat receiving medium ......................................................................................... Heat capacity (Option W2/W3) ................................................................................................... Flow rate / pressure drop (option W2) ........................................................................................ Flow rate / pressure drop (option W3) ........................................................................................ Refrigerated dryer: Compressed air system ............................................................................... Refrigerated dryer: Refrigerant circuit ........................................................................................ Danger Areas ............................................................................................................................. Safety signs ................................................................................................................................ Keys ........................................................................................................................................... Indicators .................................................................................................................................... RFID sensor field ........................................................................................................................ Energy-saving control modes ..................................................................................................... Refrigerated dryer control modes ............................................................................................... Components ............................................................................................................................... Condensate line ......................................................................................................................... Condensate collecting line ......................................................................................................... Condensate collecting line: Line diameter .................................................................................. Re-commissioning after storage ................................................................................................. Installation conditions checklist ..................................................................................................
1 2 4 4 5 5 6 6 6 7 8 8 9 9 9 9 9 10 10 11 11 12 12 13 14 14 15 15 15 16 16 17 17 18 18 19 19 19 19 20 20 27 29 37 38 39 41 42 42 51 51 51 58 58
Operator Manual CSD 100/125 T
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Rotary screw compressor
List of Tables
Tab. 55 Tab. 56 Tab. 57 Tab. 58 Tab. 59 Tab. 60 Tab. 61 Tab. 62 Tab. 63 Tab. 64 Tab. 65
viii
MODULATING control: Setting the shut-off valve ...................................................................... 61 Machine identification ................................................................................................................. 66 Remote control center identification ........................................................................................... 66 Machine identification ................................................................................................................. 67 Other faults and remedies .......................................................................................................... 69 Warn others that the machine is being serviced. ....................................................................... 71 Regular maintenance tasks ........................................................................................................ 73 Oil change intervals lubricants ................................................................................................... 74 Regular service tasks ................................................................................................................. 74 Logged maintenance tasks ........................................................................................................ 102 Spare parts ................................................................................................................................. 103
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
1
Regarding this Document
1.1
Using this document
1 Regarding this Document 1.1
Using this document The operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. ➤ Keep the operating manual in a safe place throughout the life of the machine. ➤ Supply any successive owner or user with this operating manual. ➤ Please insert any amendment or revision of the operating manual sent to you. ➤ Enter details from the machine nameplate and individual items of equipment in the table in chapter 2.
1.2
Further documents Further documents included with this operator manual are: ■
Certificate of acceptance / operating instructions for the pressure vessel
■
User manual for SIGMA CONTROL 2
Missing documents can be requested from KAESER. ➤ Make sure all documents are complete and observe the instructions contained in them. ➤ Make sure you provide the data from the nameplate when ordering documents.
1.3
Copyright This service manual is copyright protected. Queries regarding use or duplication of the documenta‐ tion should be referred to KAESER. Correct use of information will be fully supported.
1.4
Symbols and labels ➤ Please note the symbols and labels used in this document.
1.4.1
Warnings Warning notices indicate dangers that may result in injury when disregarded. Warning notices indicate three levels of danger identified by the corresponding signal word:
Tab. 1
Signal term Meaning
Consequences of disregard
DANGER
Will result in death or severe injury
Warns of an imminent danger
WARNING Warns of a potentially imminent danger
May result in death or severe injury
CAUTION
May result in a moderate physical injury
Warns of a potentially dangerous situation
Danger levels and their definition (personal injury) Warning notices preceding a chapter apply to the entire chapter, including all sub-sections. Example:
901726 08 USE
Operator Manual CSD 100/125 T
Rotary screw compressor
1
1
Regarding this Document
1.4
Symbols and labels
The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur. ➤ The measures required to protect yourself from danger are shown here. Warning notes referring to a sub-section or the subsequent action are integrated into the procedure and numbered as an action. Example: 1.
The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe injury may occur. ➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2
Potential damage warnings Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐ jury. Warning notices for damages are identified by their signal term.
Tab. 2
Signal term
Meaning
Consequences of disregard
NOTE
Warns of a potentially dangerous situation
Damage to property is possible
Danger levels and their definition (damage to property) Example:
The type and source of the imminent danger is shown here! Potential effects when ignoring the warning are indicated here. ➤ The protective measures against the damages are shown here. ➤ Carefully read and fully comply with warnings against damages.
1.4.3
Other alerts and their symbols This symbol identifies particularly important information.
2
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
Material Precondition
1
Regarding this Document
1.4
Symbols and labels
Here you will find details on special tools, operating materials or spare parts. 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
➤ This symbol denotes lists of actions comprising one stage of a task. Operating instructions with several steps are numbered in the sequence of the operating steps. Information relating to one option only are marked with an option code (e.g., H1 indicates that this section applies only to machines with machine mountings). Option codes used in this oper‐ ator manual are explained in chapter 2.2. Information referring to potential problems are identified by a question mark. The cause is named in the help text ... ➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment.
Further information
901726 08 USE
Further subjects are introduced here.
Operator Manual CSD 100/125 T
Rotary screw compressor
3
2
Technical Data
2.1
Nameplate
2 Technical Data 2.1
Nameplate The machine's nameplate provides the model designation and important technical information. The nameplate is located on the outside of the machine: ■
above the cooler, or
■
on the rear of the machine.
➤ Enter here the nameplate data as a reference: Characteristic
Value
Rotary screw compressor Part no. Year Serial no. psig cfm Voltage Hz/RPM Package FLA Phase HP Wiring Diagram FOR SERVICE, REFER TO EQUIPMENT NUMBER Tab. 3
Nameplate
2.2
Options The table contains a list of possible options. The options for this machine are shown near the nameplate. ➤ Enter options here for reference: Option
Option code
Available?
MODULATING control
C1
SIGMA CONTROL 2: Connection to control technology available
C3
✓
Power supply monitoring
C29
—
IT-three-phase network
C35
—
Bolt-down machine feet
H1
Installed: ✓ Not available: —
4
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
2
Technical Data
2.3
Weight
Option
Option code
Air-cooling
K1
Water-cooling: Plate-type heat exchanger
K2
Cooling air filter mat
K3
Water-cooling: Bundled-tube heat exchanger
K9
Transformer power supply for refrigerated dryer
T2
Heat recovery ΔT=45°F
W2
Heat recovery ΔT=99°F
W3
Available?
Installed: ✓ Not available: — Tab. 4
2.3
Options
Weight The weight given is the maximum. Actual weights of individual machines are dependent on equip‐ ment fitted. CSD 100
CSD 125
4510
4720
CSD 100
CSD 125
Minimum cut-in tempera‐ ture [°F]
40
40
Typical airend discharge temperature during oper‐ ation [°F]
150 – 200
150 – 200
Maximum airend dis‐ charge temperature [°F] (automatic safety shutdown)
230
230
Weight [lb] Tab. 5
2.4
Machine weight
Temperature
* The machine continuously changes the airend discharge temperature corresponding to the am‐ bient temperature. Tab. 6
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Temperature
Operator Manual CSD 100/125 T
Rotary screw compressor
5
2.5
2
Technical Data
2.5
Ambient conditions
Ambient conditions CSD 100
CSD 125
Maximum elevation amsl* [ft]
3000
3000
Permissible ambient tem‐ perature [°F]
40 – 115
40 – 115
Cooling air temperature [°F]
40 – 115
40 – 115
Inlet air temperature [°F]
40 – 115
40 – 115
*Higher altitudes are permissible only after consultation with the manufacturer. Tab. 7
2.6
Ambient conditions
Ventilation The values given are minimum guide values. CSD 100
CSD 125
Inlet aperture Z see fig‐ ure 15 [sq.ft.]
25 / 8.6*
29 / 8.6*
Extractor for forced venti‐ lation: Flow rate [cfm] at 0.4 in.wc
18834 6474*
21777 7063*
* Option K2/K9 Tab. 8
2.7
Ventilation
Pressure Maximum working pressure: see nameplate. Safety relief valve activating pressure [psig]: Maximum working pres‐ sure [psig]
Tab. 9
6
CSD 100
CSD 125
125
145
145
175
205
205
217
232
232
Safety relief valve activating pressure
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
2.8
2
Technical Data
2.8
Free air delivery (FAD)
Free air delivery (FAD) FAD [cfm]: Maximum working pres‐ sure [psig]
CSD 100
CSD 125
125
494
566
175
410
480
217
332
399
FAD as per ISO 1217:2009. Annex C Tab. 10
2.9
Free air delivery
Cooling Oil Recommendation A sticker showing the type of oil filled is located near the oil separator filler. Information for ordering cooling oil can be found in chapter 11.
2.9.1
Basic Information Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in compressor cooling oils. These deposits block the flow of lubricant and cause excessive wear and failure of moving parts. Contamination of the lubricant can allow the formation of acids, causing ex‐ tensive internal corrosion. Water may be condensed decreasing the lubricity. Lubricants in rotary compressors do much more than lubricate. During the compression process, it acts as a sealant in the airend which is important for maximum efficiency. The lubricant also ab‐ sorbs much of the heat of compression to cool the airend and reduce the temperature of the com‐ pressed air. It’s not enough that a compressor cooling oil lubricates well, it must stand up to the heat, pressure and contaminants that are present in every air compressor.
2.9.2
KAESER Lubricants KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do not re-use drums; flush and send to reconditioner. Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐ pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire-resistant fluid. It has a flash point above 460 °F. Since the user has total control over the condi‐ tions of the compressor lubricant, he assumes total responsibility for its safe usage. Material Safety Data Sheets are available for each lubricant from your authorized KAESER SERVICE representative. Regardless of the lubricant selected, the KAESER SIGMA lubricants will separate readily from wa‐ ter. If condensate occurs it can easily be removed. Let the compressor sit so that any water can drain back to the separator tank and separate to the bottom. See chapter 10.17 proper draining procedure. KAESER has several lubricants available that are specially formulated to match these demands. They feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long life.
901726 08 USE
Operator Manual CSD 100/125 T
Rotary screw compressor
7
2
Technical Data
2.10
Cooling oil charge
M-SERIES ■
M-Series SIGMA compressor cooling oils are semi-synthetic lubricants.
■
M-Series SIGMA compressor cooling oils are the highest quality petroleum lubricants. M–460 is specially blended to provide reliable performance in KAESER screw compressors.
S-SERIES ■
S-Series SIGMA compressor cooling oils are synthetic lubricants.
■
S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐ bricants. These ”synthetic” lubricants begin as high quality petroleum feed stock. They are then refined, processed and purified into fluids with very consistent molecular structure. These oils are carefully blended to produce extremely consistent lubricants with superior properties. SIGMA synthetic lubricants feature all the advantages of both PAO and diester fluids.
■
S-460 lubricant is recommended for compressors operating in ambient temperatures between 40 °F and 105 °F.
Specialty KAESER LUBRICANTS
2.10
■
S-680 lubricant may be used when ambient temperatures are always between 70 °F and 105 °F.
■
FG-460 synthetic hydrocarbon based food grade lubricant is designed for use in rotary screw compressors in the application where incidental food contact may occur with the discharge air. This lubricant meets the requirements of the FDA Regulation 21 CFR §178.3570 and is USDA H-1approved and NSF certified. FG-460 is approved for canning, food packing, meat and poultry processing and other applications where incidental food contact may occur.
Cooling oil charge The required cooling oil charge depends on the optional heat recovery system. For machines with options W2 or W3, the additional volume required for the heat recovery must be added to the charge.
Option K1
Air cooling CSD 100
CSD 125
Fluid volume* [gal]
13.7
13.7
Topping off volume [qt]
5.3
5.3
*Plus the oil volume of the optional heat recovery system. Tab. 11 Option K2
Cooling oil charge (Option K1) Water cooling (plate-type heat exchanger) CSD 100
CSD 125
Fluid volume* [gal]
13.2
13.2
Topping up volume [qt]
5.3
5.3
*Plus the oil volume of the optional heat recovery system. Tab. 12
8
Cooling oil charge (Option K2)
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
Option K9
2
Technical Data
2.11
Motors and power
Water cooling (bundled pipe heat exchanger) CSD 100
CSD 125
Fluid volume* [gal]
13.2
13.2
Topping up volume [qt]
5.3
5.3
*Plus the oil volume of the optional heat recovery system. Tab. 13 Option W2/W3
Cooling oil charge (Option K9) Heat recovery
Option W2
CSD 100
CSD 125
9.5
9.5
CSD 100
CSD 125
5.9
5.9
CSD 100
CSD 125
Rated power [hp]
100
125
Rated speed [rpm]
3585
3584
Protection rating
TEFC
TEFC
Motor bearing re-greas‐ ing interval [h]
2000
2000
20
25
CSD 100
CSD 125
Rated power [hp]
1.4
1.4
Protection rating
TEFC
TEFC
Additional charge vol‐ ume [qt] Tab. 14
Cooling oil charge (Option W2)
Option W3 Additional charge vol‐ ume [qt] Tab. 15
Cooling oil charge (Option W3)
2.11
Motors and power
2.11.1
Compressor drive motor
Grease requirement, each bearing [g] h = operating hours Tab. 16
2.11.2
Compressor drive motor
Option K1 Fan motor
h = operating hours
901726 08 USE
Operator Manual CSD 100/125 T
Rotary screw compressor
9
2
Technical Data
2.12
Noise emission
CSD 100
CSD 125
6000
6000
5
5
CSD 100
CSD 125
Rated power [hp]
0.16
0.16
Rated speed [rpm]
2700
2700
Protection rating
TEFC
TEFC
CSD 100
CSD 125
72 / 71*
73 / 72*
Motor bearing re-greas‐ ing interval [h] Grease requirement, each bearing [g] h = operating hours Tab. 17
2.11.3
Fan motor (Option K1)
Option K2/K9 Fan motor
Tab. 18
Fan motor (Option K2/K9)
2.12
Noise emission Mains frequency Noise emission [dB(A)]
Noise pressure level as per ISO 2151 and the basic standard ISO 9614-2; operation with maxi‐ mum working pressure; uncertainty: ±3 dB(A) * Option K2/K9 Tab. 19
Noise emission
2.13
Power Supply Basic requirements The machine is designed for an electrical supply according to National Electric Code (NEC, NFPA 70 and NFPA 79). In the absence of any user-specified alternatives, the limits given in these standards must be adhered to. Consult manufacturer for any other specific power supply. The incoming line within the control panel should be as short as possible. If external sensors or communications lines are to be connected to the machine, use shielded ca‐ bles and insert the same through EMC fittings into the control panel. Three-phase Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on power supplies such as a three-phase wye system with center point not solidly grounded or threephase (open) delta. The machine requires a symmetrical three-phase power supply transformer with a WYE configura‐ tion output as shown in Figure 1 and Figure 2. In a symmetrical three phase supply the phase an‐ gles and voltages are all the same.
10
Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
2
Technical Data
2.14
Power supply specifications
Other power supplies are not allowed.
Fig. 1
Three-phase (wye system); 4 wire; center point solidly grounded
Fig. 2
Three-phase (wye system); 3 wire; center point solidly grounded
Further information
2.14
The wiring diagram in chapter 13.4 contains further details regarding the power supply connection.
Power supply specifications The following multi-strand copper core wires are given according to 2017 NEC 310.15 and ta‐ ble 310.15(B)(16) adjusted for 40 °C ambient temperature. If other local conditions prevail, like for example high temperature, the cross section should be checked and adjusted according to 2017 NEC 110.14(C), 220.3, 310.15, table 310.15(B)(2)(a), ta‐ ble 310.15(B)(3)(a), 430.6, 430.22, 430.24, 670.4(A) and other local codes. Dual element time delay fuses are selected according to 2017 NEC 240.6, 430.52 and ta‐ bles 430.52, 430.248 and 430.250. We recommend a ground conductor the same size as the current carrying conductors, if local co‐ des allow. The minimum size as pointed out in 2017 NEC table 250.122 is NOT recommended.
Further information
The electrical diagram in chapter 13.4 contains further specifications for electrical connection. Rated power supply: 230V / 3 / 60Hz CSD 100
CSD 125
400
450
Supply per phase and ground (75 °C)
2x AWG4/0
2x MCM250 / 2x AWG4/01)
Consumption [A]
295 / 2901)
318 / 3121)
CSD 100
CSD 125
250
300 / 2501)
Pre-fuse [A]
1)
Tab. 20
Option K2/K9
Power supply details (230V / 3 / 60Hz) Rated power supply 380V / 3 / 60Hz
Pre-fuse [A] 1)
901726 08 USE
Option K2/K9
Operator Manual CSD 100/125 T
Rotary screw compressor
11
2
Technical Data
2.15
Water-cooling
CSD 100
CSD 125
Supply per phase and ground (75 °C)
2x AWG1
2x AWG1/0
Consumption [A]
176 / 1731)
200 / 1981)
CSD 100
CSD 125
200
225
Supply per phase and ground (75 °C)
2x AWG2
2x AWG1
Consumption [A]
144 / 1411)
159 / 1571)
CSD 100
CSD 125
Pre-fuse [A]
—
—
Supply per phase and ground (75 °C)
—
—
— / —1)
— / —1)
1)
Tab. 21
Option K2/K9
Power supply details (380V / 3 / 60Hz) Rated power supply: 460V / 3 / 60Hz
Pre-fuse [A]
1)
Tab. 22
Option K2/K9
Power supply details (460V / 3 / 60Hz) Rated power supply 575V / 3 / 60Hz
Consumption [A] 1)
Option K2/K9
Tab. 23
Power supply details (575V / 3 / 60Hz)
2.15
Option K2/K9 Water-cooling Cooling oil may contaminate the cooling water if a leak occurs. ➤ A special heat exchanger must be used for heating drinking water. The specific heat capacity and required volume flow rate of the cooling water changes if anti‐ freeze is added. ➤ Match the parameters of the water cooling to the properties of the cooling water. ➤ Consult an authorized KAESER SRVICE representative to ensure optimum cooling-sys‐ tem performance. ➤ Comply with the specified minimum requirements for the cooling water in order to avoid downtimes due to corrosion, calcification and contamination. It is imperative that measures for cooling water treatment and filtration are implemented and performed. KAESER can provide the names of companies specializing in cooling water analysis and the supply of suitable treatment devices.
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Operator Manual CSD 100/125 T
Rotary screw compressor 901726 08 USE
2
Technical Data
2.15
Water-cooling
The following design types are available: ■
Option K2: Water cooling with plate heat exchanger: Chapter 2.15.1
■
Option K9: Water cooling with bundled pipe heat exchanger: Chapter 2.15.2
Open cooling system An open cooling system may be a cooling circuit with open cooling towers for cooling via evapora‐ tion. As a portion of the cooling water evaporates, it must be replenished regularly. During evapora‐ tion, the material content of the cooling water concentrates and the contact with ambient air can contaminate the cooling water. When replenishing cooling water, you must ensure the minimum re‐ quirements for the cooling water. Closed cooling system In a closed cooling system, the cooling water has not contact with the atmosphere. Thus, it cannot be contaminated by the atmosphere or enriched with oxygen, for example. Continuous-flow cooling system A continuous-flow cooling system is an open cooling system. Ground, surface or drinking water cir‐ culate once through the cooling system. Further information
2.15.1
The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐ tion ports.
Option K2 Water cooling (plate-type heat exchanger) There are typical layout examples. Conditions for each individual installation could vary from these guidelines. ➤ If required, enter your individual values in the prepared table. ➤ If the design data differ, request that the settings in SIGMA CONTROL 2 are checked by an authorized KAESER service representative. The primary winding of the heat exchanger is connected to the machine. The specifications refer to the secondary side of the heat exchanger. Individual design data My value Cooling water tempera‐ ture rise [°F] Flow rate [gpm] Pressure drop [psi]
Tab. 24
901726 08 USE
Water cooling K2: Individual design data
Operator Manual CSD 100/125 T
Rotary screw compressor
13
2.15.1.1
2
Technical Data
2.15
Water-cooling
Component specification Feature
Value
Material (Heat exchang‐ er)
1.4401
Braze (Heat exchanger)
Copper (Cu)
Max. working pres‐ sure [psig]
145
Minimum permissible in‐ let temperature [°F]
41
Max. permissible inlet temperature* [°F]
104
Continuously possible outlet temperature [°F]
122
Maximum permissible outlet temperature [°F] (Component limit value)
158
Maximum permissible flow rate [gpm]
101
Unsuitable cooling media
Seawater Consult KAESER about water types.
* Consult KAESER about higher values. Tab. 25
Component specification (Option K2)
2.15.1.2
Cooling water quality Characteristics/content
Closed cooling sys‐ tem
Open cooling system
7.5 – 9.0
7.5 – 9.0
0 – 20
0 – 20
Carbonate hardness [°dH]
