KAESER SK 19 Service Manual Download

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Table of Contents

Chapter --- Page

Putting into Operation

7 --- 22

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7.1

Points to be Observed before Putting into Operation

7 --- 22

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7.2

Points to be Observed before Starting the Compressor Unit

7 --- 22

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7.3

Checklist

7 --- 24

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7.4

Direction of Rotation Check

7 --- 25

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7.5

Motor Overload Relay Adjustment and Changing

7 --- 26

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7.6

Setting the Air System Pressure

7 --- 27

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7.7

Functional Check of the Door Interlock Switch

7 --- 28

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7.8

Measures to be taken before Initial Start

7 --- 30

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7.8.1

Pour a small quantity of oil into the air inlet port

7 --- 30

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7.8.2

Running the compressor in idle

7 --- 30

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Operation

8 --- 31

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8.1

Control Panel

8 --- 31

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8.2

SIGMA controller

8 --- 31

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8.2.1

Emergency Stop Pushbutton

8 --- 31

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8.2.2

Function keys

8 --- 32

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8.2.3

Light emitting diodes and plain text display

8 --- 32

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8.3

Starting and Stopping the Compressor Unit

8 --- 33

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8.4

Acknowledgement of Alarms

8 --- 33

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8.5

Acknowledgement of Service Messages

8 --- 34

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8.6

Faults: Possible cause --- Remedy

8 --- 35

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8.6.1

Working temperature too high

8 --- 35

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8.6.2

Motor overload protection relay trips

8 --- 35

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8.6.3

Compressor runs but does not reach pressure.

8 --- 36

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8.6.4

Oil leaks out of air filter

8 --- 36

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8.6.5

Full---load/Idle sequence occurs too frequently (short cycles)

8 --- 37

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8.6.6

Safety relief valve blows off

8 --- 37

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8.6.7

Oil in the package

8 --- 37

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8.6.8

Excessive oil consumption

8 --- 37

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Maintenance

9 --- 39

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9.1

Observe the following rules during all maintenance and servicing work:

9 --- 39

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9.2

Regular Maintenance

9 --- 40

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9.3

Opening and Closing the Compressor Package

9 --- 41

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9.4

Checking the Drive Belt Tension

9 --- 42

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9.5

Drive Belt Change

9 --- 42

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9.6

Cleaning or Replacing the Filter Mat

9 --- 43

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9.7

Cleaning or Replacing the Air Filter

9 --- 44

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9.8

Servicing the Electric Motor

9 --- 44

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9.9

Testing the Safety Relief Valve on the Oil Separator Tank

9 --- 45

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9.10

Venting the compressor unit

9 --- 45

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9.11

Oil Filter Change

9 --- 46

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9.11.1 Removal and replacement of the oil filter cartridge

9 --- 46

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9.12

Oil Top ---Off

9 --- 47

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9.13

Cleaning the Oil Cooler and Aftercooler

9 --- 49

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Summary of Contents for SK 19

Page 1: ...L Nr BA SK19 L 1 9760 50011 00 03 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 L L Switchable Modulation L L Synthetic lubricant L Wiring Diagram L Food Grade lubricant Serial No ...

Page 2: ...nces 2 7 2 2 General Safety Precautions 2 8 2 3 Electrical Power Supply 2 9 2 4 Spare Parts 2 9 2 5 Compressed Air System 2 9 2 6 Environmental Protection 2 10 3 General 3 11 3 1 Proper use of the Compressor 3 11 3 2 Improper use 3 11 3 3 Compressed Air Treatment 3 11 3 4 Copyright 3 11 4 Transport 4 12 4 1 Transport Instructions 4 12 4 2 Packaging 4 12 4 3 Storage 4 13 5 Construction and Operatio...

Page 3: ...Messages 8 34 8 6 Faults Possible cause Remedy 8 35 8 6 1 Working temperature too high 8 35 8 6 2 Motor overload protection relay trips 8 35 8 6 3 Compressor runs but does not reach pressure 8 36 8 6 4 Oil leaks out of air filter 8 36 8 6 5 Full load Idle sequence occurs too frequently short cycles 8 37 8 6 6 Safety relief valve blows off 8 37 8 6 7 Oil in the package 8 37 8 6 8 Excessive oil cons...

Page 4: ... 2 Oil top off 9 53 9 14 3 Draining the oil using own compressed air 9 54 9 14 4 Procedure for putting back into operation 9 54 9 15 Changing the Oil Separator Cartridge 9 55 9 16 Maintenance Schedule 9 57 10 Spare Parts and After Sales Service 10 58 10 1 Service parts and maintenance parts 10 58 10 2 Service and Maintenance Agreement 10 59 11 Appendix 11 60 11 1 Wiring Diagram 11 60 11 2 Spare Pa...

Page 5: ...ings Dimensional drawing T 7471 5 P I flow chart FSK19STL 00022 00 Pipework and instrument flow chart Electrical diagram SSK19 Y U1013 00 1 2 Noise Level Noise level to CAGI Pneurop 67 dB A at 1 m distance free sound field measurement 1 3 Motor Compressor motor Rated power 15 hp Rated speed 3600 rpm Specification class TEFC 1 4 Electrical Connection Main voltage 230 V 3 phase Full load current FLA...

Page 6: ... Activating pressure 155 psig 145 psig Compressor Unit Activating pressure 175 psig 190 psig Compressor Unit Activating pressure 230 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 distributor Min ambient temperature 40 EF Max ambient temperature 105 EF Min cooling air inlet air temperature 40...

Page 7: ...l con trol over the conditions of the compressor lubricant he assumes total responsibility for its safe usage Material Safety Data Sheets are available for each lubricant from your KAESER authorized distributors Regardless of the lubricant selected the KAESER Sigma lubricants will separate readily from water If condensate occurs it can easily be removed Let the compressor sit so that any water can...

Page 8: ...ing and other applications where incidental food contact may occur SPECIALTY KAESER LUBRICANTS Refer to product information to determine suitability SIGMA LUBRICANT DESCRIPTION MAXIMUM RECOMMENDED CHANGE INTERVAL First Oil Change Subsequent Oil Change S 680 FG 460 ISO 68 Synthetic Lubricant ISO 46 Food Grade Synthetic Fluid 6 000 Hours 2 000 Hours 8 000 Hours 3 000 Hours Oil changes may need to be...

Page 9: ...an be etched by any synthetic lubricant We recommend replacement with metal bowls or the addition of metal guards 1 9 Maintenance for the Electrical Motor Relubricate the compressor motor bearings Under normal operating conditions after 12000 h ambient temperature up to 77EF Under unsuitable conditions after 6000 h ambient temperature up to 105EF but no later than 3 Years operating hours 1 10 Dime...

Page 10: ...Technical Specification 1 6 ...

Page 11: ...in this service man ual This symbol is placed by text where considerable attention must be paid so that recommendations regulations references and correct se quence of work are adhered to and that damage and or destruction of the compressor unit and or other equipment is prevented This symbol identifies environmental protection measures This symbol indicates operations to be carried out by the ope...

Page 12: ...accordance with applicable lock out tag out pro cedures example OSHA CFR 29 1910 147 Unless the Service Manual states otherwise all pressure lines must be vented or shut off Any alterations or reconstruction carried out without the prior written authorization of KAESER COMPRESSORS Inc will invalidate the war ranty No welding heat treatment or mechanical modifications may be car ried out on pressur...

Page 13: ...quirements with regard to ex plosion protection are applied 2 3 Electrical Power Supply The main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC OSHA and any appli cable local codes Compressor packages must be installed with a lockable main discon nect and fuses or other short circuit and ground fault protection de vice For fuse and wire ...

Page 14: ...ions Maintenance materials wear items replacement parts Ensure that all wear items maintenance and replacement parts accu mulating during operation of the compressor package are disposed of according to environmental regulations The following points must be observed Avoid contact with skin and eyes Do not inhale vapors and oil mist Do not eat or drink when handling such materials Fire open flame a...

Page 15: ...rational and maintenance instructions laid down by the manufacturer If the compressor package is operated in an air distribution network the maximum network pressure may not exceed 232 psig The equipment may only be used or serviced by authorized and trained personnel 3 2 Improper use Never direct compressed air toward persons Compressed air is a con centrated form of energy and as such is dangero...

Page 16: ... 2 Packaging Always observe the instructions in chapter 4 3 when packaging the machine for storage Use packaging suitable for the intended route if the machine is to be transported further by the customer Overland The machine should be protected from mechanical damage by a sturdy crate and from moisture by plastic sheeting By sea or air Special packaging instructions can be obtained from KAESER Di...

Page 17: ...age for longer than 6 months are to be taken Storage for longer than 6 months Ensure the equipment is dry and cover in plastic sheeting Protect the interior with suffi cient quantities of desiccant silica gel or similar Storage for longer than 12 months Carry out the following additional maintenance tasks before putting into operation Change the oil filter see chapter 9 11 Change the oil separator...

Page 18: ...c tion bearings The compressed air and oil mixture leaves the airend via the discharge port 4 5 6 1 2 3 1 Drive shaft 4 Male rotor 2 Oil injection 5 Female rotor 3 Discharge port 6 Air inlet port 5 2 Brief Description The compressor block is driven by an electric motor via V belts An oil separator cartridge is fitted into the oil separator tank allowing practically oil free compressed air supply T...

Page 19: ...Construction and Operation 5 15 ...

Page 20: ...Construction and Operation 5 16 ...

Page 21: ...ge runs in idle for longer than the preset period 1 to 2 for example t1 6 min the drive motor is stopped completely 2 When the lower switching point pmin 3 is reached the compressor package is automatically started again Pressure rises to the upper switching point pmax 4 and the compressor package switches to idle If the pressure falls again to for example pmin 5 within a shorter period 4 to 5 the...

Page 22: ...g point These two periods are set according to the maximum permissible cut in frequency of the compressor motor The running period starts every time the compressor package is switched on It lasts as long as the compressor motor runs and stops when the compressor package switches to full stop The idle standstill period starts every time the operating mode changes from full load to off load running ...

Page 23: ...ssor is switched to standstill after the run on period has ex pired 3 If the pressure decay time tpdecay was shorter than the period set for the idle stand still period the idle mode is selected 4 that is the inlet valve closes and the com pressor is vented with running motor When the running period expires the com pressor package switches to standstill only after the run on period has also expire...

Page 24: ...nd against the ingress of dust and rain Install the compressor according to the following diagram Adhere to the minimum dis tances shown to allow free access to the compressor package Adequate ventilation of the compressor space is ensured only if the minimum values see chapter 1 6 are adhered to A B min 90 h 32 32 40 Exhaust ventilator Exhaust duct Measurements in inches Air inlet opening A min 9...

Page 25: ...wer supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC OSHA and any appli cable local codes For fuse and wire recommendations see chapter 1 4 The compressor is wired ready for connection to the main supplies Feed the supply cable with cores marked L1 L2 L3 and PE through the cable inlet in the base frame into the con trol box and connect to the te...

Page 26: ...ING ATTENTION DANGER CAN LEAD TO ACCIDENTS CAUSING IN JURY TO PERSONS OR DAMAGE TO EQUIPMENT If a power failure occurs the compressor package starts again auto matically normal setting provided the line pressure is lower than the pressure threshold parameter entered in SIGMA CONTROL Do not operate the compressor with open maintenance doors or with cover panels removed as personnel could be injured...

Page 27: ...e ball valve 6 6 see chapter 5 3 must be closed The ball valve 20 see chapter 5 3 must be open Lock the main disconnect in the off position in accordance with ap plicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart Check all screws on the electrical connections for tightness and tighten if necessary carry out this check again after 50 hours of...

Page 28: ...nditions yes no Is a shut off valve fitted by the user yes no Is a flexible connecting hose or axial compensator fitted between the compressor package and the compressed air system yes no Have all screws bolts and electrical connections been checked for tightness yes no Has the oil level in the oil separator been checked yes no Is a main disconnect switch fitted suited to the motor starting charac...

Page 29: ... Arrows showing the direction of rotation are located on the motor and on the airend hous ing On your initial start bump the unit and verify the direction of rotation If the direction of rotation is incorrect change over the supply conductors L1 and L2 If the airend rotates in the wrong direction the compressor is auto matically shut down by the safety air pressure switch 4 2 see chapter 5 3 Atten...

Page 30: ...ints see wiring diagram In the Wye delta configuration the phase current is fed through the motor overload relay This phase current is 0 58 times the nominal motor current For the nominal motor current see motor nameplate Adjustment To prevent the overload relay from tripping because of voltage fluctuations temperature influences or component tolerances the value can be set up to 15 higher than th...

Page 31: ...changed in SIGMA CONTROL to match customer s operational requirements if the password is known For further details consult the SIGMA CONTROL service manual Switching from full load to idle running may take place no more fre quently than 2 times per minute Switching frequency can be improved by increasing the difference between cut in and cut out pressure In addition a larger air receiver can be in...

Page 32: ...maintenance door If the insertion key 3 at the door interlock is incorrectly aligned inad vertent shutdown of the compressor package can occur The insertion key 3 aligns with the door interlock switch 1 without binding against the sides of the interlock switch when the maintenance door is closed If necessary re align the insertion key 3 Loosen the bolts 4 Align the insertion dey 3 so that it glide...

Page 33: ... must be made after in itial start Start the compressor package see chapter 8 3 Open the left hand maintenance door the compressor package will shut down im mediately if the door interlock switch functions correctly Close the left hand maintenance door Reset the alarm message by pressing the acknowledge reset key 11 see chapter 8 2 2 on SIGMA CONTROL The compressor package is now ready to start ag...

Page 34: ...his oil must be of the same type as the oil used to operate the com pressor see label near the oil filler plug on the oil separator tank If no additional oil is available remove required amount of oil from the oil separator tank See chapter 9 14 for this procedure If the compressor unit was at standstill for more than 12 months addi tional precautionary steps have to be taken before putting the un...

Page 35: ...ible alarms and service messages display of events etc are given in the service manual sup plied for the SIGMA CONTROL controller 8 2 1 Emergency Stop Pushbutton The Emergency Stop pushbutton shuts down the compressor package immediately If the Emergency Stop pushbutton is pressed because of an existing hazard then this must be eliminated before the compressor package is reset To accomplish this t...

Page 36: ...Remote ON key 9 Return key 5 Load idle key 10 Info event key 11 Acknowledge reset key 8 2 3 Light emitting diodes and plain text display 12 13 19 14 15 16 17 18 20 21 12 Four line display 17 Load LED 13 Alarm LED 18 Idle LED 14 Communication alarm LED 19 Compressor ON LED 15 Warning maintenance LED 20 Remote ON LED 16 Power ON LED to controller 21 Timer ON LED ...

Page 37: ...l Press the OFF key 2 LED 19 extinguishes Lock the main disconnect in the off position in accordance with applicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart See chapter 2 3 for the main disconnect switch 8 4 Acknowledgement of Alarms If an alarm occurs the compressor package is shut down immediately and the red LED 13 on SIGMA CONTROL flas...

Page 38: ...tion is included in the SIGMA CONTROL service manual Carry out the maintenance work Acknowledge service message with the reset key 11 LED 15 extinguishes When the respective maintenance has been carried out the remaining interval period programmed interval until the next maintenance is due must be reset Detailed information on resetting service counters is to be found in the service manual for SIG...

Page 39: ...ogged by deposits Have an authorised KAESER service agent inspect clean or replace the heat exchanger as necessary Air inlet filter mats clogged Clean or replace the filter mats Fluid level too low Top up to the correct level with recom mended cooling fluid Check and clean the dirt trap strainer in the fluid scavenge line Thermostatic valve not functioning cor rectly Check valve spring and activat...

Page 40: ...tor connections Inlet valve not opening or only opening partially Have the valve inspected by an autho rized KAESER Service Technician Venting valve not closing under full load Check the combination control venting valve and lines and pipework Replace defective parts Minimum pressure check valve defec tive Have the valve inspected by an autho rized KAESER Service Technician Leaks in the machine Ti...

Page 41: ...cartridge pressure differen tial and replace cartridge if necessary Minimum pressure check valve does not open Check the valve for blockage and re place defective parts as necessary Safety relief valve not properly sized for the pressure of the compressor unit Check blow off pressure and com pare to name plate of the compressor Replace if necessary 8 6 7 Oil in the package Possible cause Remedy Ma...

Page 42: ...eparator cartridge mountings are loose Tighten mounting bolts Oil level in separator tank is too high Drain oil to correct level Scavenger line is clogged Inspect dirt trap strainer in scavenger line Clean or replace clogged parts as necessary ...

Page 43: ...re latched back on again and all maintenance doors are closed before restarting the compressor unit To start the compressor unit see chapter 8 3 The venting nozzle required to vent the oil separator tank for mainten ance work such as topping up the oil oil change and filter change is fitted to the hose coupling 3 see chapter 9 10 Carry out a visual and functional check of the door interlock switch...

Page 44: ...to 3000 h or at least annually Replace the oil filter 9 11 Proper interval varies See chapter 1 8 Change the oil 9 14 up to 9000 h or at least every 3 years Change the oil separator cartridge 9 15 Annually Check all electrical connections for tightness and tighten if necessary 12000 h Have the valves inspected by an authorized KAESER Service agent Annually Have the safety relief valve checked by a...

Page 45: ...the arrow and lift up the maintenance door 2 Loosen the screws B and remove the panel 3 To close Close the panel 3 the maintenance door 2 and the maintenance door 1 in the re verse order Close all maintenance doors and panels correctly before starting the compressor package A B 3 1 2 B 1 Maintenance door 2 Maintenance door 3 Cover panel ...

Page 46: ...o the point where the indicator pin 3 is situated at the top end of its indicator slot Loosen the hexagonal nut 2 Tension the belt drive with the hexagonal nut 1 until the indicator pin 3 is situated at the bottom end of its indicating slot Tighten the hexagonal nut 2 9 5 Drive Belt Change Switch off the compressor unit see chapter 8 3 Lock the main disconnect switch in the off position in accorda...

Page 47: ...off the compressor package see chapter 8 3 Lock the main disconnect switch in the off position in accordance with applicable lockout tagout procedures to ensure the compressor does not restart 1 3 2 2 3 3 3 1 Filter 2 Holding frame 3 Closure Press closures 3 inwards and remove the holding frame Cleaning Rinse the mat in warm water approximately 105 F if necessary use a mild detergent soap to rinse...

Page 48: ...maged Clean all sealing surfaces Cleaning the air filter cartridge with compressed air Use dry compressed air blowing at a pressure of not more than 30 psig at a slant from the inside to the outside of the air filter cartridge surfaces Do not clean the air filter cartridge with fluids If the air filter cartridge is heavily contaminated or was already cleaned several times max five times replace Co...

Page 49: ... unit see chapter 8 3 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 closed position and vent all compressed air trapped between the compressor and the isolation shut off valve in accordance with applicable lock out tag out pro cedures The oil circulation syst...

Page 50: ...gain Close all maintenance doors and panels correctly before starting the compressor package 9 11 Oil Filter Change Hot oil beware of scalding Replace the run in oil filter cartridge with a standard oil filter cartridge supplied with the compressor after approximately 200 operating hours Change the oil fillter cartridge according to the regular maintenance schedule see chapter 9 2 or when the corr...

Page 51: ... Perform a test run When the operating temperature is reached see chapter 1 1 shut down the compressor package see chapter 8 3 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 ensure the compressor does not restart Afterwards carry out a visual check for leaks 9 12 Oil Top Off Check the oil level weekly throu...

Page 52: ...pen the isolation shut off valve between the compressor and the compressed air system After an oil change or oil cooler cleaning with removal of the oil cooler run the compressor package up to operating temperature to ensure that the combination valve closes and that the oil cooler is flooded with oil Afterwards repeat the procedures Venting the Compressor Package chapter 9 10 and Topping off the ...

Page 53: ...ut tag out procedures to ensure the compressor does not restart Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized Venting the compressor package see chapter 9 10 9 13 1 Removing and cleaning the oil cooler air aftercooler 1 1 2 3 4 1 Allen screw 2 Hose screw fitting 3 Pipe screw fitting 4 Pipe screw fitt...

Page 54: ... cleaning areas with oil separators suited for such purpose Clean the cooler laminations with compressed air water or steam jet Seat the O rings correctly in the compressed air inlet of the oil air aftercooler during reassembly Reassemble in the reverse order See chapter 9 12 for topping off the oil Open the isolation shut off valve between the compressor and the compressed air system Perform a te...

Page 55: ...e end will result in a whipping action which could cause severe injury or death If the compressor package operates in ambient temperatures close to the maximum ambi ent temperature see chapter 1 6 change the oil more often e g 1 2 or 1 4 of recom mended interval Drain the oil out of the oil separator tank cooler and the oil pipes com pletely See chapter 9 14 4 for putting back into operation If a ...

Page 56: ...valve 1 Insert the nozzle 6 in the hose coupling 3 on the oil separator tank 5 Connect the nozzle to external pressure source Pressurize the oil separator tank 5 until the pressure gauge 2 on the oil separator tank 5 shows approximately 43 5 psig Remove the nozzle 6 from the hose coupling 3 on the oil separator tank 5 Drain the oil from the oil separator tank Prepare a clean container to catch esc...

Page 57: ...the oil drain plug 1 back in tightly Dispose of the old oil according to environmental regulations 9 14 2 Oil top off Unscrew the oil filler plug 4 on the oil separator tank 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...

Page 58: ... position in accordance with ap plicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does not restart Check the actual pressure on the pressure gauge 2 Open the shut off valve 1 let the pressure on the pressure gauge 2 sink to approximately 40 psig and then close the shut off valve 1 again Drain the oil from the oil separator tank and the oil cooler Proceed as...

Page 59: ...il filters We recommend that the oil separator cartridge is changed with the oil or when the relevant service message alarm message is displayed on SIGMA CONTROL see chapter 8 1 Stop the compressor package under full load see chapter 8 3 Lock the main disconnect in the off position in accordance with ap plicable lock out tag out procedures example OSHA CFR 29 1910 147 to ensure the compressor does...

Page 60: ...urfaces make sure that no dirt particles fall into the oil separator tank The oil separator cartridge is a disposable item and cannot be cleaned Insert the new O ring 9 in the groove in the oil separator tank Insert the new oil separator cartridge 8 with new gaskets 6 fit and tighten down the cover plate 5 with the hexagonal bolts 4 Replace the screen filter 11 and the gasket 10 when the oil separ...

Page 61: ...Maintenance 9 57 9 16 Maintenance Schedule Model No Serial No Date Description of work Operating hours Signature ...

Page 62: ...ER Part No Serial No Voltage Package FLA Drive Motor FLA MADE IN GERMANY Important for spare parts orders Enter the data on the compressor name plate in the name plate shown above Always quote the data on the name plate when ordering spare parts Always order original spare parts from the compressor manufacturer to avoid lower quality spare parts in your compressor unit Supplementary information fo...

Page 63: ...eparating cartridge Gasket O Ring Dirt screen filter Gasket 1 1 2 1 1 1 1450 V belt set 1 1800 10 2 Service and Maintenance Agreement We recommend that you take out a service and maintenance agreement with an author ized KAESER distributor This is your best guarantee of reliable air supplies ...

Page 64: ...Appendix 11 60 11 Appendix 11 1 Wiring Diagram ...

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