KAESER KOMPRESSOREN OMEGA 4 B, Assembly And Operating Manual

Page 1: ...Assembly and operating manual Blower block OMEGA 4 B Number 9_9533 23 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...

Page 2: ...KKW BOMBB 2 03 en SBA OMEGA_4_B 20150401 133922...

Page 3: ...fety and Responsibility 3 1 Basic instructions 9 3 2 Intended use 9 3 3 Improper use 9 3 4 User s responsibilities 10 3 4 1 To be noted when integrating in a machine 10 3 4 2 Observe statutory and uni...

Page 4: ...31 10 3 Checking the oil level 31 10 4 Replenishing lubricating oil 32 10 5 Changing the oil 33 10 6 Checking rotors for contamination 34 10 7 Documenting maintenance and service work 35 11 Spares Ope...

Page 5: ...flow direction vertical 18 Fig 4 Permissible angle deviation 21 Fig 5 Checking the oil level 32 Fig 6 Replenishing lubricating oil 32 Fig 7 Changing the oil 33 Fig 8 Transport with a crane 39 List of...

Page 6: ...List of Illustrations iv Assembly and operating manual Blower block OMEGA 4 B Number 9_9533 23 E...

Page 7: ...ble intake temperature 7 Tab 17 Sound pressure level 8 Tab 18 Sound power level 8 Tab 19 Danger areas 14 Tab 20 Safety signs 15 Tab 21 Installation options 21 Tab 22 Installation conditions checklist...

Page 8: ...List of Tables vi Assembly and operating manual Blower block OMEGA 4 B Number 9_9533 23 E...

Page 9: ...icable directives 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 w...

Page 10: ...his symbol indicates particular important information Material Here you will find details on special tools operating materials or spare parts Precondition Here you will find conditional requirements n...

Page 11: ...ght B8 Direction of rotation left B11 Direction of rotation right B12 Operating mode Vacuum B14 Rotors 2 lobe B15 Material rotors Spheroidal graphite iron B17 Material rotors Stainless steel B18 Mater...

Page 12: ...on B19 84 115 Rotors Stainless steel Option B18 Enclosure Grey cast iron Option B19 86 118 Rotors Stainless steel Option B18 Enclosure Ni Resist Option B20 87 121 Tab 4 Weight 2 4 Pressure 2 4 1 Optio...

Page 13: ...The effective flow rate is dependent on speed and pressure conditions Further information The design diagrams in chapter 13 2 contain specifications of effective flow rate delivery 2 6 Power and spee...

Page 14: ...ction OMEGA 41 B OMEGA 43 B Inlet port DN mm 80 100 Discharge port DN mm 80 100 Tab 10 Connection dimensions 2 9 Temperature Delivery medium OMEGA 41 B OMEGA 43 B Maximum block dis charge temperature...

Page 15: ...ng oil charge l recommended values Flow direction Drive end Control end Vertical Option B5 0 25 15 0 30 15 Tab 14 Lubricating oil charge 2 12 Ambient and intake conditions OMEGA 41 B OMEGA 43 B Permis...

Page 16: ...SO 2151 and basic standard ISO 9614 2 Measurement distance 1 m Sound pressure level dB A Operating mode OMEGA 41 B OMEGA 43 B Vacuum Option B14 81 90 81 93 Tab 17 Sound pressure level Sound power leve...

Page 17: ...for any damages that may result from incorrect use The user alone is liable for any risks incurred Comply with the instructions in this operating manual Operate the blower block only within its perfor...

Page 18: ...personnel possess the following qualifications are of legal age have read understood and will abide by the safety instructions and operating manual must be fully conversant with the safety concepts a...

Page 19: ...with foodstuffs if compressed air can come into contact with them Quality of discharge air The quality of the discharge air and any substances it may contain depends on the quality of the air drawn fr...

Page 20: ...blower block Modifications additions or conversions to or of the blower block can result in unpredictable haz ards Do not permit conversion or modification as this can compromise function and safe wo...

Page 21: ...t without danger or hindrance Do not operate in areas in which specific requirements with regard to explosion protection are in force For instance the requirements of ATEX directive 94 9 EC Equipment...

Page 22: ...ng to environmental regulations Return the blower block to KAESER for disposal and attach the completed Declaration of Con tamination 3 6 Danger areas The table gives information on areas dangerous to...

Page 23: ...ck out the power supply disconnecting device Tab 20 Safety signs 3 8 In emergency 3 8 1 Correct fire fighting Suitable extinguishing agents Foam Carbon dioxide Sand or earth Unsuitable or unsafe extin...

Page 24: ...th regard to warranty A condition of our warranty is the specified use of the blower block under observation of the specif ic operating conditions Due to the numerous applications for which the blower...

Page 25: ...ing so no oil film lubrication is nee ded 4 2 Options The design of the blower block is defined by options Option code for Flow direction Position and direction of rotation of the drive shaft view to...

Page 26: ...2 Flange connection both ends 3 Drive end oil inlet 4 Drive end oil drain 5 Drive shaft 6 Drive end oil sight glass 7 Gear end oil sight glass 8 Connection for measuring device 9 Gear end oil drain 4...

Page 27: ...ired ambient conditions are maintained Do not operate the block without pipework or silencers connected to the inlet and outlet Required ambient conditions may be Maintain ambient temperature and humi...

Page 28: ...ty concerns relate to any work on components that could be under pressure Close shut off valves or otherwise isolate the block from the air distribution network to ensure that no compressed air can fl...

Page 29: ...der pressure De pressurise all pressurised components and enclosures CAUTION Rotating rotors Danger of squashing or severing Do not reach into the interior of the block Permissible angle deviation in...

Page 30: ...he blower block may be driven by readily available drives Precondition The drive power should be at least 12 more than required by the block 1 Drive the block only in the specified direction of rotati...

Page 31: ...re needed for secure operation of the machine into which the blower block is installed Blow off or vacuum valve to prevent exceeding or falling short of the permissible operating pressure The initial...

Page 32: ...the permissible limits are reached of Temperature Pressure or vacuum Current draw Carefully assess the installation situation and seek advice from KAESER Further information Design diagrams are given...

Page 33: ...late the block from the air distribution network to ensure that no compressed air can flow back into the block De pressurise all pressurised components and enclosures Further information Details of au...

Page 34: ...d when the block is coupled to the drive Necessary meas ures are dependent on the design of the drive and should be determined by the user An arrow indicating direction of rotation is fixed on the sid...

Page 35: ...low Frozen condensate and highly viscous lubricating oil can cause damage when starting the ma chine Make sure that the temperature of the block is at least 3 C before starting the machine 2 The bloc...

Page 36: ...ps of rotor and or enclosure wall worn Contact KAESER Service Delivery medium water vapour excessive high temperatures at the discharge port Check the injection cooling sys tem Too much leakage from t...

Page 37: ...overloaded Contact KAESER Service Water in the oil Condensate build up by pro longed storage and high humid ity Change the lubricating oil Gas drains closed Remove transport plugs of the two gas drai...

Page 38: ...ork to ensure that no compressed air can flow back into the block De pressurise all pressurised components and enclosures Further information Details of authorised personnel are found in chapter 3 4 3...

Page 39: ...can be determined upon analyses of the oil Tab 25 Regular maintenance tasks 10 2 3 Regular service tasks The table below lists necessary service tasks Only an authorised KAESER Service Technician shou...

Page 40: ...he pressure system Precondition The power supply disconnecting device is switched off The disconnecting device is locked in the off position The oil level has settled NOTICE Unsuitable oil can damage...

Page 41: ...terial Lubricating oil Oil receptacle WARNING Danger of burns from hot components and oil Wear long sleeved clothing and gloves Fig 7 Changing the oil 1 Plug drive end oil filling port 2 Plug gear end...

Page 42: ...ating device is switched off the device is locked off the absence of any voltage has been verified The block has cooled down WARNING Danger of burns from hot components Wear long sleeved clothing and...

Page 43: ...enance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 27 Logged maintenance tasks 10 Maintenance 10 7 Documenting maintenance and service work...

Page 44: ...may result from damage Use only original KAESER parts and operating fluids materials Have an authorised KAESER Service Technician carry out regular maintenance Name Number Lubricating oil 1600 Tab 28...

Page 45: ...blower block 11 5 1 Shipment of the blower block Precondition Correct preparation of the block for shipment 1 Drain the oil 2 Close off the oil drain port 3 Close off the flange connections 4 Appropri...

Page 46: ...ails of conserving oils are found in chapter 12 4 12 2 Packing A crate is required for overland transport to protect the block from mechanical damage Consult KAESER Service for advice concerning sea o...

Page 47: ...ston Danger of squashing or severing of limbs Do not reach into the interior of the block Store the block in a dry room Protect the flange connections drive shaft and delivery space of the block by sp...

Page 48: ...ndition Blower block without oil Flange connections are closed Return the block to KAESER 12 Decommissioning Storage and Transport 12 5 Disposal 40 Assembly and operating manual Blower block OMEGA 4 B...

Page 49: ...le deviation of the base surface to the levelness 0 05 mm 6 Drainage 7 Optional 8 Minimum safety distance for pulleys 9 Pressure gauge connection 22 Option code 57 two sided 70 Oil sight glass positio...

Page 50: ...Original Blatt Sprache Name Datum Ma stab Projektion nderungs Nr E Released Dimension and connection dim 1 4 HECK1 HECK1 HECK1 08 01 2015 08 01 2015 31936 OMEGA 4 1 B 01 03 2013 1 von 1 Dokument TZM...

Page 51: ...z Original Blatt Sprache Name Datum Ma stab Projektion nderungs Nr E F R E I G E G E B E N Dimension and connection dim 1 4 HECK1 HECK1 HECK1 14 03 2013 14 03 2013 31936 OMEGA 4 1 B 28 02 2013 1 von 1...

Page 52: ...here Diagram legend A Vacuum operation Intake state air at 20 C final pressure 1013 mbar B p mbar C Blower speed min 1 D Blower shaft power kW E Intake capacity m3 min relative to the intake condition...

Page 53: ...Blower speed rpm 500 400 300 200 100 1 2 3 4 5 6 7 8 9 10 11 100 200 300 400 500 0 20 40 60 80 100 120 500 400 300 200 100 B p mbar B p mbar B p mbar E Inlet capacity m 3 min referred to inlet condit...

Page 54: ...peed rpm 500 400 300 200 100 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 100 200 300 400 500 0 20 40 60 80 100 120 500 400 300 200 100 B p mbar B p mbar B p mbar F Temperature increase K E Inlet...

Page 55: ...in the chosen language a translation can be found here Diagram legend A Vacuum gauge pressure operation Intake condition Air at 20 C final pressure 1113 mbar B p mbar C Blower speed min 1 D Blower sh...

Page 56: ...20 40 60 80 100 120 500 400 300 200 100 B p mbar B p mbar B p mbar E Inlet capacity m 3 min referred to inlet conditions A Vacuum gauge pressure operation Inlet conditions air at 20 C discharge press...

Page 57: ...00 300 400 500 0 20 40 60 80 100 120 500 400 300 200 100 B p mbar B p mbar B p mbar A Vacuum gauge pressure operation Inlet conditions air at 20 C discharge pressure 1113mbar F Temperature increase K...

Page 58: ...13 3 Declaration concerning contamination 13 Annex 13 3 Declaration concerning contamination 50 Assembly and operating manual Blower block OMEGA 4 B Number 9_9533 23 E...

Page 59: ..._________________________________________________ Cleaning method ____________________________________________________________ Information on contaminants with what substances has the item been in con...

Page 60: ...13 Annex 13 3 Declaration concerning contamination 52 Assembly and operating manual Blower block OMEGA 4 B Number 9_9533 23 E...