Kaishan KRSL Series, Instruction Manual

Page 1: ...PN 96002018000001 Release August 2022 Version B USA Kaishan Rotary Screw Air Compressor KRSL Series Instruction Manual Direct Drive...

Page 2: ...TION 8 2 2 THE COMPRESSION CYCLE 9 2 3 MOTOR 9 2 4 COMPRESSOR LUBRICATION AND COOLING SYSTEM 10 2 5 COMPRESSOR DISCHARGE SYSTEM 10 2 6 AIREND INLETVALVE AND FILTRATION SYSTEM 12 Fluid Information 13 3...

Page 3: ...UCTURE 23 5 3 TECHNICAL DATA 32 5 4 THROUBLESHOOTING 33 Servicing 33 6 1 FLUID CHANGE 34 6 2 AIR FILTER 34 6 3 FLUID FILTER 35 6 4 AIR OIL SEPARATOR 35 6 5 FLUID SAMPLING PROCEDURE 35 6 6 MAINTENANCE...

Page 4: ...ds are used throughout this manual The level of hazards seriousness is symbolized as follows This symbol identifies immediate hazards which will result in severe personal injury death or substantial p...

Page 5: ...URE A properly sized pressure relief valve must be installed in the discharge piping ahead upstream of any shutoff valve block valve heat exchanger orifice or any potential blockage point Failure to i...

Page 6: ...is designed for use in the compression of normal atmospheric air only No other gases vapors or fumes should be exposed to the compressor intake nor processed through the compressor Keep personnel away...

Page 7: ...tions and descriptions cover KRSL series air compressors As a service to our customers we often modify or construct packages to the customer s specifications This manual may not be appropriate in thos...

Page 8: ...package consists of following Compressor Air End Electric motor Starter Air Inlet System Compressed Air Discharge System Lubrication and Cooling System Capacity Control System Instrumentation Panel A...

Page 9: ...discharge port The compressed air is then discharged into the air oil separator tank There are five complete compression cycles for each complete rotation of the male rotor When the compressor is oper...

Page 10: ...o the compressor The thermal valve is a directional valve with a temperature sensitive device The thermal valve fully closes the access to the fluid cooler when the fluid temperature is below 70 C 158...

Page 11: ...oir fluid level Fluid is added to the reservoir by removing the fluid filling cap after all system pressure is relieved The fluid level should remain at the top red line on the sight glass Fluid refil...

Page 12: ...essor inlet system consists of an air filter inlet valve SKY airend The inlet valve controls the air intake volume It is also acts as the check valve to prevent the reverse pressure and rotation when...

Page 13: ...ervoir The compressor is filled with the manufacturer s recommended quantity of Kaishan fluid Inspection of the reservoir fluid level during installation or operation is recommended Figure 3 1 Fluid F...

Page 14: ...hours or as indicated by sampling report Every 2 000 hours or as indicated by Delta P Every 8 000 hours or as indicated by Delta P KTL4000 FG Every 4 000 hours or as indicated by sampling report Ever...

Page 15: ...e placed under the bottom of the base if floor surface is uneven or irregular NOTICE Brand new compressor has Orange Color shipping bracket installed under airend assembly Please remove the bracket af...

Page 16: ...water resistant but not water tight Shelter is needed to protect the unit from rain snow and freezing temperatures An optional weather hood or air grille could be installed to protect compressor agai...

Page 17: ...to thermal expansion Piping support brackets must be mounted independent of the compressor and motor This will avoid damage caused by vibration Pressure relief valves are sized to protect the system...

Page 18: ...ng units to a building s structural steel may not provide adequate grounding protection as paint and corrosion build up may exist All electrical supply cables must be adequately sized to prevent overh...

Page 19: ...4 7 FAN ROTATION INSPECTION Fan motor rotation should be inspected KRSL compressors uses a centrifugal fan for cooling Fan rotation is inspected through an arrow shaped observation hole above the fan...

Page 20: ...ouch screen display Line Pressure Discharge Temperature Current Voltage Fan Status Compressor Status Total Run Hours Total Load Hours Run Parameters User Parameters Factory Parameters Calibration Set...

Page 21: ...hen in running state Push to save data when modifying text box When on Icons Page push to execute the corresponding function When Controller is in Alarm press and hold for 5 seconds to Reset Push this...

Page 22: ...ns If activated the following Icons will appear on the Normal Run Screen A Time Schedule has been set A Pressure Schedule has been set Auto Restart is engaged Remote Stop Start activated Computer Visu...

Page 23: ...Pressure Differential 00 55MPa Display oil pressure differential Front Rotor T 0065 C Display front rotor temperature Rear Rotor T 0065 C Display rear rotor temperature Oil Filter 0020H Display Runnin...

Page 24: ...fer to Digital Input 41 Low Water Flow 4 Refer to Digital Input 40 Oil Filter DP 5 Refer to Digital Input 39 Separator DP 6 Refer to Digital Input 38 Air Filter DP 7 Refer to Digital Input 36 Multi Fu...

Page 25: ...KW Hr Display Fan Power Consumption in Real Time Fan Power Total Consump OOO O KW Hr Display accumulative Fan Power Consumption Fan State Description 0000 Fan Running Status from Inverter data read Er...

Page 26: ...tart if Discharge Temperature is above this setting Fan Stop T C F 0070 158 Fan will stop if Discharge Temperature is below this setting Motor Start Delay S 0008 Set to bypass Motor Overload protectio...

Page 27: ...Transducer Start Mode Local Remote Stop and start from MAM Controller Will start from MAM Controller and remote contacts Run Mode 5 options DOL Motor VSD Fan VSD Motor Fan VSD Soft Start Comm Address...

Page 28: ...ss Enter and Confirm MAM 6090 has the capacity to control 16 compressors via a daisy chain RS485 series link utilizing RS485 1 terminals A1 B1 and GND1 MENU DEFAULT FUNCTION Highlight text to be modif...

Page 29: ...trol Compressor a Go to User Menu b Set COMM MODE to BLOCK c Set COM ADD to OOO1 for Master Unit d After setting turn off Controller and Reboot to save this setting To Set Slave Compressors a Go to Us...

Page 30: ...reasing it has to be manually reset Oil Filter Max Run Time H 2000 Alarm Prompt Hours Set to OOOO and function is disabled Air Oil Separator Max Run Time H 2000 Alarm Prompt Hours Set to OOOO and func...

Page 31: ...Start and Load if Between Start and Stop Schedule Time Set if air pressure is below this setting Unload P Mpa PSI 00 80 116 00 Will Unload if Between Start and Stop Schedule Time Set if air pressure...

Page 32: ...0VA 9 RTD Range 50 350 C 58 284 F TEMP C TEMP F Ohms 20 4 0 92 16 10 14 0 96 09 0 32 0 100 10 50 0 104 20 68 0 107 79 30 86 0 111 67 40 104 0 115 54 50 122 0 119 4 60 140 0 123 24 70 158 0 127 07 80 1...

Page 33: ...heck the power and contactors Overload Voltage too low tubes block bearing wear off or other mechanical failure or wrong set data etc Check the set data voltage bearings tubes and other mechanical sys...

Page 34: ...The 1 4 turn valve on the blow down valve MUST be open for the unit to blow down during regular unit operation 6 2 AIR FILTER The standard Kaishan air filter is a single stage dry type element Air fi...

Page 35: ...ter element Replacement requires unbolting and lifting the separator cover and replacing it with a new one The air oil separator should be replaced as indicated in the maintenance schedule or as follo...

Page 36: ...lean air filter Clean after cooler fins Check for loose fluid and air tubing electrical wiring connection Every 1000 hours Clean air filter or replace with new element Clean after cooler fins Every 20...

Page 37: ...k voltage and power source or contact local power company High operating pressure Reset check line pressure and ensure it does not exceed the compressor s maximum operating pressure Low fluid level To...

Page 38: ...y Faulty safety valve Repair or replace as necessary Excessive oil carry over in discharge compressed air High oil level Check oil level Scavenging line blocked Clean or replace as necessary Low disch...

Page 39: ...leak Check and replace as necessary Pressure setting Change setting above 1Bar Receiver tank too small Check or increase volume of receiver tank Air flow into the main network restricted Increase pipe...

Page 40: ...y inconsistent terms and conditions contained herein or elsewhere Prices The prices of the Products are those prices specified on the front of the invoice or contained within an agreed written contrac...

Page 41: ...he manufacturer including any transferable 90 days warranty is given for service parts from receipt date Seller warrants to Buyer that Products purchased hereunder will conform to the applicable manuf...

Page 42: ...war strike delay by carrier shortage of Product acts or omissions of other parties acts or omissions of civil or military authority Government priorities changes in law material shortages fire strikes...

Page 43: ...Page 43 KRSL series Contact Information Kaishan Compressor LLC Add 15445 Industrial Park Dr Loxley AL Post code 36551 Office number 1 251 202 0577...