KAESER SM 8 Service Manual
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KAESER SM 8 Service Manual

KAESER SM 8 Service Manual

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SERVICE MANUAL
Screw Compressor
Model: SM 8
GL---Nr.: BA---SM8.L---1.9620.80030---00
Index: 090201
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Wye---Delta Start
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D.O.L. Start
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Wiring Diagram:
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Serial No.:
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KAESER COMPRESSORS, Inc.
P .O. Box 946 : Fredericksburg, Virginia 22404 : Tel. (540) 898---5500 : Fax. (540) 898---5520
Back to Table of Contents
USA
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Volt
Cabinet heaters
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115 V receptacle
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Outdoor modification
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psig
Rainhoods
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Switchable Modulation
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Synthetic lubricant
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Food Grade lubricant . . . . . . . . . . . . . . . . .
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  • Page 1 Back to Table of Contents SERVICE MANUAL Screw Compressor Model: SM 8 GL---Nr.: BA---SM8.L---1.9620.80030---00 Index: 090201 ......

  • Page 2: Table Of Contents

    Table of Contents Chapter --- Page Technical Specification ......... 1 --- 1 Compressor Unit .
  • Page 3 Table of Contents Chapter --- Page 7.7.2 Running the compressor in idle ........7 --- 24 7.7.3 Checklist...

  • Page 4: Technical Specification

    ..........SM 8 Maximum gauge working pressure .

  • Page 5: Set Point Of The Safety Relief Valve

    Installation Requirements Max. height above sea level of the place of installation 3000 ft. (for all heights above please contact authorized KAESER distributor) 40 EF Min. ambient temperature ......

  • Page 6: Oil Recommendations

    M -- SERIES SEMI -- SYNTHETIC LUBRICANTS M---Series SIGMA compressor fluids are the highest quality petroleum lubricants. M---460 is specially blended to provide reliable performance in KAESER screw com- pressors. S-- SERIES SYNTHETIC LUBRICANTS S---Series SIGMA compressor oils are formulated from the most advanced synthetic lubricants.
  • Page 7 9.14 proper draining procedure. Compatibility of KAESER Sigma Lubricants All the above listed KAESER Sigma lubricants are similar to mineral oil in its compatibility with paints, seals, gaskets and hoses. The typical precautions are required when changing over from mineral oil to KAESER synthetic hydrocarbon based lubricant.

  • Page 8: Maintenance For The Electrical Motor

    Technical Specification ACCEPTABLE NOT RECOMMENDED Viton Celcon High Nitrile Buna N Neoprene Teflon SBR Rubber Epoxy Paint Low Nitrile Buna N Oil Resistant Alkyd Acrylic Paint Nylon Lacquer Delrin Polystyrene Attention! Polycarbonate bowls can be etched by any synthetic lubricant. We recommend replacement with metal bowls, or the addition of metal guards.
  • Page 9 Technical Specification 1 --- 6...

  • Page 10: Safety Regulations

    (example: OSHA CFR 29 § 1910.147). Attention! Any alterations or reconstruction carried out without the prior written authorization of KAESER COMPRESSORS Inc. will invalidate the war- ranty. 2 --- 7...

  • Page 11: Electrical Power Supply

    These recommendations do not supersede other applicable codes. Spare Parts Safe and reliable operation of the compressor package is guaranteed only with KAESER original spare parts and KAESER SIGMA cooling oil. Compressed Air System If a compressed air system is extended or changed, verify that the blowoff pressure and capacities of the safety relief valves on the air receiver tanks and in the system match the rating of all the compressor packages installed.

  • Page 12: Environmental Protection

    Safety Environmental Protection Condensate drainage The condensate accumulating during compression must be fed via a suitable drainage system, collected in special canisters and disposed of according to environmental regulations. 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.

  • Page 13: General

    Copyright KAESER COMPRESSORS, INC. All rights reserved. No part of this manual may be reproduced in any form without per- mission of KAESER COMPRESSORS, INC. 3 --- 10...

  • Page 14: Transport

    Transport Transport Transport Instructions We recommend a fork lift truck or lifting equipment for transporting the compressor pack- age to avoid damage to the cabinet and framework. min. 32” Attention : Do not exert any side forces on the compressor unit when transporting with lifting equipment! Packaging The packaging provided with this compressor as delivered is intended to safeguard the...

  • Page 15: Construction And Operation

    Construction and Operation Construction and Operation Principle of Compression The stationary compressor package is fitted with a single stage, oil---injected airend. The two rotors, the driven male rotor and the female rotor, both mounted in antifriction bear- ings, are fitted into the airend. As the rotors rotate, air is drawn into the upper side through the inlet port and is compressed on the lower side.
  • Page 16 Construction and Operation 5 --- 13...
  • Page 17 Construction and Operation 5 --- 14...

  • Page 18: Dual Control

    Construction and Operation DUAL Control Full load Idle Standstill Time In DUAL Control (combined idle and start ---stop) the compressor normally runs at full -- load, idle or standstill. The controller regulates the compressor package between full -- load and idle. If the compressor package runs in idle for longer than the preset period (1) to (2), for example t = 6 min, the drive motor is stopped completely (2).

  • Page 19: Quadro Control

    Construction and Operation QUADRO Control p min Full load Idle Standstill Time rise decay Running period Idle/ standstill period Run ---on period Stop point for the running period or idle / standstill period upper switching point lower switching point pressure rise time (the time during which the air system pressure rises rise from the lower to the upper switching point) pressure decay time (the time during which the air system pressure decays...

  • Page 20: Vario Control

    Construction and Operation If the air systems pressure rises to the upper switching point and the running period has already expired, the compressor package is switched off after the run ---on period has expired (2). If the air systems pressure rises to the upper switching point before the running period has expired then the pressure decay time of the previous switching cycle is taken as the criterium for the selection of the operating mode: -- If the pressure decay time t...

  • Page 21: Installation

    Installation Installation Installation Requirements Attention! The compressor should be mounted on level surface. For any special application please consult with the manufacturer. Safe operation of the compressor package is only ensured if the ambient temperature re- mains within the limits stated in chapter 1.6). If the compressor is used in the open, take care that it is protected against the direct rays of the sun and against the ingress of dust and rain.

  • Page 22: Connection Of The Compressed Air Supply

    Installation Solution B: Exhaust Air used for Space Heating The hot air is forced through a conduit (see chapter 1.6) into the room to be heated. Attention! Consult the manufacturer with regard to length of conduit and for maximum allowable pressure drop for this compressor package. Safe operation of the compressor package is guaranteed only if the temperature limits (see chapter 1.6) of the cooling air are adhered to.

  • Page 23: Putting Into Operation

    Initial Start Putting into Operation Points to be Observed before Putting into Operation Every compressor package is given a test run at the factory and carefully inspected before shipment. The test run confirms that the package conforms to the specification data and runs perfectly.

  • Page 24: Functional Check Of The Door Interlock Switch

    Initial Start If exhaust air ducts are to be installed the duct cross section must be equal or larger than the cooling air outlet of the compressor package and may not exceed the per- mitted pressure loss prescribed by the compressor manufacturer. During installation of the compressor package, ensure that a distance of at least 40 ”...
  • Page 25 Initial Start Attention! 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) align with the door interlock switch (1) without binding against the sides of the interlock switch when the maintenance door is closed.

  • Page 26: Direction Of Rotation Check

    Initial Start Direction of Rotation Check Attention! The compressor is wired for connection to a clockwise phase se- quence power supply. A check of the direction of rotation can be made by testing the phase sequence. Arrows showing the direction of rotation are located on the motor and on the airend hous- ing.

  • Page 27: Measures To Be Taken Before Initial Start

    Initial Start Measures to be taken before Initial Start Follow the procedure detailed bellow before initial start, after an oil change or if the com- pressor has not been operated for a period of three months or longer before starting the compressor: 7.7.1 Pour a small quantity of oil into the air inlet port...

  • Page 28: Checklist

    Initial Start 7.7.3 Checklist  Is the floor at the place of installation solid and level?  yes  no  Is the space large enough for the compressor package or its components?  yes  no  Are inlet and exhaust air apertures available in sufficient size and number?  yes  no  Are all components of the compressor package easily accessible?  yes  no...

  • Page 29: Operation

    Operation Operation Control Panel 1 SIGMA CONTROL 2 EMERGENCY STOP pushbutton SIGMA CONTROL Operation of the compressor package is determined by the parameters preset in the con- troller and can differ from the standard settings described because of requirements spe- cific to a customer.

  • Page 30: Function Keys

    Operation 8.2.1 Function keys 1 ON key (”I”) Menu scroll --- DOWN key 2 OFF key (”0”) Menu scroll --- UP key 3 Timer ON/OFF key Escape key 4 Remote ON key Return key 5 Load/idle key Info --- event key Acknowledge (reset) key 8.2.2 Light emitting diodes and plain text display...

  • Page 31: Starting And Stopping The Compressor Unit

    Operation Starting and Stopping the Compressor Unit Attention! Do not start and stop the compressor package with the main discon- nect switch. The compressor must always be switched ON and OFF with keys (1) and (2). To turn the compressor ON (local):  Switch on the main disconnect switch.

  • Page 32: Acknowledgement Of Service Messages

    Operation Acknowledgement of Service Messages When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes. Attention! Before any maintenance is due an initial warning is displayed to allow coordination of service and maintenance personnel and provision of necessary servicing materials. (lubricants, spare parts, etc.). Maintenance due is shown in the display (12).

  • Page 33: Maintenance

    Maintenance Maintenance Observe the following rules during all maintenance and servicing work: Work on power driven equipment may only be carried out by trained or specialized personnel. Follow all applicable OSHA and local safety regulations. 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.

  • Page 34: Regular Maintenance

    6000/12000 hours or at Have the compressor motor bearings relubrica- least within three years ted by autherized KAESER distributors* * The maintenance period can vary depending on the cycle rate and environmental conditions. * * Not to exceed 2000 service hours.

  • Page 35: Opening And Closing The Compressor Cabinet

    Maintenance Opening and Closing the Compressor Cabinet To open:  Open the access door (1).  Pull the locking lever (3, photo A) outwards, turn 90• in the direction of the arrow and latch onto the frame.  Lift the panel (2) and remove. To close:  Turn the locking lever (3) to its initial position.

  • Page 36: Checking The Drive Belt Tension

    Maintenance Checking the Drive Belt Tension  Switch off the compressor unit (see chapter 8.3). Lock the main disconnect switch in the ”off” position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart. Check the tension of the belt drive after the first 2 and 24 hours of operation and thereafter every 500 hours of operation.

  • Page 37: Drive Belt Change

    Attention! (each set) and absolutely oil -- proof. For this reason we recommend that only original KAESER drive belts are used.  Place the new V---belts over the motor and compressor pulleys without straining them.  Set the belt drive tension (see chapter 9.4).

  • Page 38: Cleaning Or Replacing The Air Filter

    Maintenance Cleaning: Rinse the mat in warm water ( approximately 105•F), if necessary, use a mild detergent soap to rinse out oily dust. The mat can also be tapped, vacuum cleaned or blown out with compressed air (not in excess of 30 psig). If the mat is heavily soiled or has been cleaned often (maximum five Attention! times), replace it.

  • Page 39: Servicing The Electric Motor

    SIGMA CONTROL. See chapter 1.5 for the safety relief valve activating pressure. Attention! Have the safety relief valve tested by an authorized KAESER distribu- tor in accordance with the maintenance schedule (see chapter 9.2). For more details see SIGMA CONTROL manual.
  • Page 40 Maintenance Venting the oil separator tank: 1 Ball valve 4 Filler plug 8 Screwed sealing plug A shut (oil top ---off) (oil cooler) B open 5 Oil separator tank 9 Ball valve --- oil drain 2 Pressure gauge 6 Nozzle 10 Hose coupling 3 Hose coupling 7 Oil level...

  • Page 41: Oil Filter Change

    Maintenance 9.11 Oil Filter Change Hot oil; beware of scalding. Replace the run-- in oil filter cartridge with a standard oil filter cartridge Attention! (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 corresponding service message is displayed on SIGMA CON- TROL (see chapter 8.1).

  • Page 42: Oil Top

    Maintenance Attention! Do not use a tool as this may cause damage to the oil filter cartridge and the gasket.  Check the oil level (see chapter 9.12).  Open the isolation shut ---off valve between the compressor and the compressed air system.
  • Page 43 Maintenance 1 Ball valve 4 Filler plug 8 Screwed sealing plug A shut (oil top ---off) (oil cooler) B open 5 Oil separator tank 9 Ball valve --- oil drain 2 Pressure gauge 6 Nozzle 10 Hose coupling 3 Hose coupling 7 Oil level 11 External pressure source  Unscrew the oil filler plug (4) on the oil separator tank.

  • Page 44: Cleaning The Oil Cooler And Aftercooler

    Maintenance 9.13 Cleaning the Oil Cooler and Aftercooler The oil cooler and air aftercooler must be checked for clogging regularly. Heavy contami- nation could lead to excessive temperatures in the oil circulation system. See regular maintenance schedule for cooler maintenance interval (chapter 9.2).  Switch off the compressor package under full load (see chapter 8.3).
  • Page 45 Maintenance 5 Hexagonal nut 6 Allen screw  Unscrew the hex bolt (5). The hex socket head bolts (6) are located behind two protective caps. Attention! Before unscrewing the two hex socket head bolts (6) prop up the com- bination oil/air aftercooler.  Remove the protective caps and unscrew the two hex socket head bolts (6).

  • Page 46: Oil Change (Oil Separator Tank And Oil Cooler)

    Maintenance 9.14 Oil Change (Oil Separator Tank and Oil Cooler) For type of oil and frequency of oil change see chapter 1.8 Oil change must be carried out with warm to the touch condition of the compressor pack- age (Oil temperature approx. 104•F). Danger of scalding with hot oil.

  • Page 47: Oil Change Using External Pressure Source

    Maintenance 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). 9.14.1 Oil change using external pressure source  Close the ball valve (1).  Insert the nozzle (6) in the hose coupling (3) on the oil separator tank (5).

  • Page 48: Oil Top

    Maintenance 9.14.2 Oil top -- off  Unscrew the oil filler plug (4) on the oil separator tank. Attention! 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.

  • Page 49: Procedure For Putting Back Into Operation

    Maintenance 9.14.4 Procedure for putting back into operation  Refer to chapter 7.7.1 and follow the instructions in section ‘‘Pouring a small quantity of oil into the air inlet port” .  Refer to chapter 7.7.2 and followthe instructions in section ”Running the compressor package in idle”.
  • Page 50 Maintenance 1 Spring 6 O ---Ring (dia.80x8mm) 11 Dirt trap 2 Hose coupling 7 Groove 12 Elbow fitting 3 Pressure gauge 8 Oil separator cartridge 13 Control line 4 Hexagonal nut 9 O ---Ring (dia.80x3,5mm) 5 Cover 10 Groove Grounding the oil separator cartridge is by means of a spring, inset and clamped in the separator cover (5).
  • Page 51 Maintenance  Insert the control air pipe (13) into the elbow fitting (12) and tighten up the union nut.  Open the isolation shut ---off valve between the compressor and the compressed air system. 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”...

  • Page 52: Maintenance Schedule

    Maintenance 9.16 Maintenance Schedule Model No....... . Serial No......Date Description of work Operating hours...

  • Page 53: Spare Parts And After Sales Service

    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. 10 --- 50...

  • Page 54: Appendix

    Appendix Appendix 11.1 Wiring Diagram 11 --- 51...

  • Page 70: Trouble Shooting: Possible Cause

    Cooling air supply is inadequate. Provide required amount of ventilation. If cooling air outlet duct is used it may Consult authorized KAESER distributor be too narrow or too long. for duct requirements. On air cooled units the fins of the cool-...

  • Page 71: Compressor Is Running But Produces No Pressure

    Appendix Possible cause: Remedy: Motor is running two phase: defective Check input power, check wiring, tigh- motor or blown fuse. ten any loose connections. Replace fuse(s) or motor if necessary. Oil separator cartridge is contamina- Check pressure differential across car- ted.

  • Page 72: Oil Leaks Out Of Air Filter

    Full -- load/Idle sequence occurs too frequently (short cycles) Possible cause: Remedy: Receiver tank size is too small or there Consult authorized KAESER distributor is no tank. for recommended tank size. Diameter of hose connecting the unit Connecting hose diameter should not to the receiver tank is too small.

  • Page 73: Excessive Oil Consumption

    Possible cause: Remedy: Wrong oil is being used in the unit. Replace with correct oil type. Consult authorized KAESER distributor for other oil types not listed. Oil separator cartridge has ruptured. Check pressure differential and re- place oil separator cartridge if neces- sary.
  • Page 74 SM 8 SM 11 A 08 B 07 C 14 D 11...
  • Page 75 SECTION 1 INTRODUCTION 1.FOREWORD This manual is provided for the operator’s use and reference when ordering parts. An illu- strated parts breakdown is included for identification. All compressor parts meet the manu- facturer’s highest quality used in the manufacture of the original equipment. 2.
  • Page 77 Frame,Casing Ref. Qty. Part.-No. Description Ref. Qty. Part.-No. Description 207150.0 Frame 206309.0 Door 207163.0 Casing 207160.0 Door 207156.0 Change frame 6.1891.0 Filtre mat 207167.0 Filtre frame 238 ¼“ 5.1398.0 Gasket pofile 6.1335.0 Rubber buffer dia. 50 x 45 6.0720.0 Hex.-head screw M6 x 16 6.0624.0 Washer 6.0685.0...
  • Page 79 Set of v-belts 6.2511.0 Set of v-belts 1-4) 4.9660.0 Ring 5-8) 4.9769.0 Ring 1) Unit SM 8 110 psig 2.7911.1 Swing frame 2) Unit SM. 8 125 psig 2.7905.1 Whip 3) Unit SM 8 145 psig 4.9687.0 Balance adjustment 4) Unit SM 8 190 psig 2.7916.0...
  • Page 81 Oil tubes SM Ref. Qty. Part.-No. Description Ref. Qty. Part.-No. Description 3.5242.10020 Tank 2.3 gal 6.0432.0 Gasket G 1/4 6.1893.0 Oil separator cartridge 6.1521.0 Gasket G 3/8 4.8640.5 Inlet valve 6.1523.0 Gasket G 1/2 200505.10010 Silencer 6.0761.0 Hex. head screw M 10 x 20 1,2,3) 4 4.8690.20010 Combination valve...
  • Page 83 Control tubes,Compressed air tubes Ref. Qty. Part.-No. Description Ref. Qty. Part.-No. Description 5.3141.0 Foil label 4.8680.1 Minimum pressure check valve G 3/4 7.1422.0 Pressure switch 14.5 psig 7.7040.0 Pressure transducer 0-232 psig 2.9207.0 Lock nut 7.7035.0 Resistance thermometer 6.0432.0 Gasket G 3/8 7.3629.0 Emergency stop button 5.3040.0...

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