Kaishan KRSD Series Bedienungsanleitung
PN: 96002018000001
Release: May 2018, Version: A
KRSD Series
Rotary Screw
Air Compressor
Instruction
Manual
(Controller MAM-200)
KRSD series Page 2
TABLE OF CONTENTS
1. Safety Information…………………...………………………………………………4
1.1 Safety Alert Symbols………………………………………………………………4
1.2 Safety Precautions………………………………………………...………………...5
1.3 Pressure……………………………………..……………………………………….5
1.4 Fire and Explosion…………………………..……………………………………...6
1.5 Moving Parts………………………………………………..………………………6
1.6 Hot Surfaces…………………………….………………………….……………….6
1.7 Proper Compressed Air Applications......................................................6
1.8 Electrical Shock……………………………………………….…………………….7
2. General Information……………………………………………………………………8
2.1 Introduction…………………………………………………………………………8
2.2 The Compression Cycle…………………………………………………………….9
2.3 Compressor Lubrication and Cooling System…………………………..……...10
2.4 Compressor Discharge System…………………………………….……………..10
2.5 Air-end, Inlet Valve and Filtration System…………………………………….11
3. Fluid Information……………………………………………………………………..12
3.1 Fluid Guide………………………………………………………………….……..12
3.2 Fluid Change and Recommendations……………………………………....……13
4. Installation……………………………………………………………………………..14
4.1 Compressor Mounting, Support and Location…………………………………14
4.2 Ventilation and Cooling……………………………………….…………………14
4.3 Piping Connection………………………………………………………..............15
4.4 Fluid Level Inspection………………………………………….…………………16
4.5 Electrical………………………………………..…………………………………17
4.6 Motor Rotation Inspection…………………………………………...…………...17
4.7 Fan Rotation Inspection …………………………………………….……………18
5. Operation…………………………………………………………………….………...19
5.1 Routine Operation…………………………………………….…………………..19
5.2 Electronic controller basic operation…………………………………………20
5.3 Technical Parameters and functions…………………………… ………………29
Page 3KRSD series
5.4 Model and specifications…………………………………………………………30
5.5 Installation………………………………………………………………………31
5.6 Alarms………………………………………………………………………….34
5.7 Controller protection…………………………………………………………….35
6. Servicing………………………………………………………………………………..38
6.1 Fluid Change……………………………………………………………..……..38
6.2 Air Filter……………………………………………………………………….…..38
6.3 Fluid Filter………………………………………………………………………....39
6.4 Air/Oil Separator………………………………………………………………….39
6.5 Fluid sampling procedure……………………………………………………….39
6.6 Maintenance Schedule…………………………………………………………….40
7. Troubleshooting Guide.………………………………………………………………42
8. Standard Terms and Conditions ……………………………………………….…..45
KRSD series Page 4
Safety Information
Thank you for choosing Kaishan Compressor. Please read this instruction manual carefully
before using the compressor. This manual must be kept in the safe place for future
reference. Kaishan Compressor’s authorized distributors provide maintenance service for
KRSD series rotary screw compressors. A certified technician is required to ensure
compressors maintenance is safely handled. By following the instructions in this manual,
the user will minimize possibility of an accident throughout the useful life of this
equipment.
1.1 SAFETY ALERT SYMBOLS
Key hazards 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
properly damage.
This symbol identifies hazards or
unsafe practices which could
result in personal injury, death or
substantial property damage.
This symbol identifies immediate
electrical hazards which will result
in severe personal injury, death or
substantial properly damage.
This symbol identifies hazards or
unsafe practices which could
result in personal injury or
substantial property damage.
This symbol identifies immediate
hot surface hazards which will
result in severe personal injury.
NOTICE
Identifies important installation,
operation or maintenance
information which is not hazard
related.
Page 5KRSD series
1.2 SAFETY PRECAUTIONS
This manual describes the safety precautions, structure, and functions of all systems and
components, as well as the operation and maintenance methods for the KRSD series rotary
screw air compressors. The owner and operator shall read the manual carefully. Only after
thorough understanding should the machine be operated for the first time. This manual
gives you a general description of the mechanical and electrical systems and maintenance.
However, if you have any questions about operating and maintenance of the compressor,
please contact your authorized distributor or our service department personnel.
Do not modify the compressor and/or controls in any way except with written factory
approval. While not specifically applicable to all types of compressors with all types of
prime movers, most of the precautionary statements contained herein are applicable to most
compressors and the concepts behind these statements are generally applicable to all
compressors.
Failure to follow any of these precautions may results in severe personal injury,
death, property damage and/or compressor damage
1.3 PRESSURE
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 install a pressure relief valve could result in the rupturing or
explosion of some system components. Relieve all pressure internally to the compressor
prior to servicing. Do not depend on check valves to hold system pressure. Do not change
the pressure setting of the pressure relief valve, restrict the function of the pressure relief
valve, or replace the pressure relief valve with a plug. Over pressurization of system or
compressor components can occur resulting in death, severe personal injury, or property
damage. Do not operate the compressor at pressures in excess of its rating. Never use
plastic pipe, rubber hose, or soldered joints in any part of the compressed air system.
Failure to ensure system compatibility with compressor piping is dangerous
KRSD series Page 6
1.4 FIRE AND EXPLOSION
Clean up any spills of lubricant or combustible liquid immediately. Keep sparks and flame
away from the compressor. Do not permit smoking during servicing, such as checking or
adding fluid. Wipe down spills immediately using industrial cleaner as required. Do not use
flammable material for cleaning purposes. Do not operate the compressor in a hazardous
environment unless the compressor has been specially designed for that environment. Wear
personal protective equipment including safety goggles and clothing during servicing the
compressor. Never use a flammable or toxic solvent for cleaning the air filter or any parts.
1.5 MOVING PARTS
Keep hands, arms and cloths away from the coupling and fans of the compressor. Do not
remove any guards or cabinet panels or attempt to service any compressor part while the
compressor is operating.
1.6 HOT SURFACES
Do not touch any hot surface and parts during the compressor’s operation. Keep all body
parts away from air/oil receiver tank, steel tubing, air end and after-cooler. Wear personal
protective equipment including gloves while servicing the compressor.
1.7 PROPER COMPRESSED AIR APPLICATIONS
Air from this compressor will cause severe injury or death if used for breathing or food
processing. Air used for those processes must meet OSHA and applicable industry
regulations. This compressor 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 from the compressed air discharge.
Use compressed air for cleaning purpose only with effective chip guarding and personal
protective equipment which meet OSHA standard and/or any federal, state, local codes,
standard and regulation.
Page 7KRSD series
1.8 ELECTRICAL SHOCK
Never start the compressor unless it is safe to do so. Do not attempt to operate the
compressor with a known unsafe condition. Tag the compressor and render it inoperative
by disconnecting and locking out all power at the source or otherwise disabling its prime
mover so others who may not know of the unsafe condition cannot attempt to operate it
until the condition is corrected. Install, use and operate the compressor only in full
compliance with all pertinent OSHA regulations and/or any applicable Federal, State, and
Local codes, standards and regulations. Never assume it is safe to work on the compressor
because it is not operating. Many installations have automatic start/stop controls and the
compressor may start at any time.
NOTICE
- Follow all maintenance procedures and check all safety devices on schedule.
- Use the correct compressor fluid at all time
- Do not rely on the discharge check valve to isolate the compressed air service line
- Keep panels closed at all times, and stay away from hot surfaces to prevent
hazards
NOTICE
These instructions, precautions and descriptions cover KRSD 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 those cases.
Every effort has been taken to ensure complete and correct instructions have been included
in this manual. However, possible product updates and changes may have occurred since
printing this manual. Kaishan Compressor USA reserves the right to change specifications
without incurring any obligation for equipment previously or subsequently sold.
KRSD series Page 8
General Information
2.1 INTRODUCTION
The KRSD series offer models with power ranging from 30 hp to 50 hp. These direct
driven compressors have standard full load pressure rating from 100 psi to 175 psi (7 bar to
13 bar). The compressor is a single stage, positive displacement, fluid-flooded rotary screw.
A complete 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
Air and Fluid Cooling System
Air/ Fluid separation tank (Reservoir)
All components are assembled on a structural steel base with enclosure. The control panel
is located in the front of the enclosure door panel. Acoustical enclosure is one of the
standard features for all compressors.
NOTICE!
Dismantling the compressor’s enclosure may void its warranty.
Page 9KRSD series
2.2 THE COMPRESSION CYCLE
The compressor housing contains of two rotors; Male and
Female rotors. The male rotor has five lobes and female rotor
has six flutes. They are constantly and precisely meshed, and
housed in the cylinder with two parallel adjoining bores. All
parts are machined to exacting tolerances. The rotors provide
positive-displacement internal compression smoothly and
without surging. As the rotors rotate, air is drawn into the
cylinder through the inlet port. A volume of air is filled and
trapped as the rotor lobes pass the inlet port in the cylinders.
Compression occurs as the male rotor rolls into the female
flute, progressively reducing the space thereby raising the
pressure. Compression continues until the lobe and flute pass
the 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 operating, a partial vacuum is produced at the compressor inlet.
Fluid is injected into the compressor unit and mixed with the air. The fluid has three basic
functions:
As a coolant, it controls the rise in air temperature normally associated with the heat
of compression.
It seals the leakage paths between the rotors and stator and also between the rotors
themselves.
It acts as a lubricating film between the rotors allowing one rotor to directly drive
the other, which is an idler.
After air/fluid mixture is discharged from compressor to the reservoir, fluid is separated
from the air in the separator tank. Compressed air then flows through the after-cooler for
moisture removal while the lubricant is being cooled by the fluid-cooler for re-injection.
KRSD series Page 10
2.3 COMPRESSOR LUBRICATION AND COOLING SYSTEM
The lubrication and cooling system consists of a reservoir, centrifugal fan, fan motor,
aluminum finned fluid-cooler and after-cooler, thermal valve & fluid filter. High pressure
forces the lubricant through a series of direction changes in the reservoir where it is
separated from the air. The fluid is then delivered to the thermal valve and fluid-cooler.
Cooled fluid will be filtered before being re-injected back into the compressor.
Ambient air is being forced through the cooler fins by the centrifugal fan, which cools the
fluid and compressed air in the cooler tubes. The after-cooler helps separate the water
content in the discharge air, and through the automatic condensate drain, the water will be
drained. This avoids water contamination problems downstream (in service lines). Cooler
fins must be kept clean at all times.
Fluid from reservoir circulates to the thermal valve. The thermal valve is fully closed when
the fluid temperature is below 70°C (158°F). Fluid (below 158°F) will bypass the thermal
valve and inject directly to the airend. As the discharge temperature rises above 80°C
(176°F), due to heat of compression, the thermal valve begins to open and fluid will be
circulated to the cooler.
2.4 COMPRESSOR DISCHARGE SYSTEM
Air/fluid mixture has been forced into reservoir after compression. The reservoir has two
basic functions:
It acts as a primary fluid separator.
It serves as the compressor fluid sump.
The compressed air/fluid mixture enters the reservoir and is directed against the internal
baffle. Turbulent flow occurs, and velocity is significantly reduced, thus causing large
droplets of fluid to form and fall to the bottom of reservoir. Fluid collected in the reservoir
will then be returned to the compressor due to the pressure differential.
The sight glass enables the operator to visually monitor the reservoir 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 lines on the sight glass. Fluid refill is required
once its level drops below the lower red line.
The minimum pressure check valve assures the reservoir maintains a minimum pressure
between 58 psig and 72 psig (4Bar and 5Bar) during unloading conditions. This pressure is
necessary for air/fluid separation and fluid circulation.
Andere Handbücher für KRSD Series
1
Dieses Handbuch passt für folgende Modelle
10
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