KAESER KOMPRESSOREN HBPI pr User manual

Installation and Operating Manual
Rotary lobe blower
HBPI pr
Number: 9_9572 28 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
www.kaeser.com

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IN ANY WAY. ALTERATION OF THE INFORMATION CONTAINED HEREIN MAY RESULT IN MISUSE OF
EQUIPMENT WHICH COULD RESULT IN SERIOUS INJURY. KAESER COMPRESSORS, INC. ASSUMES NO
LIABILITY FOR ANY ALTERED INFORMATION. The information may also contain privileged and confidential
information. Under no circumstances may this document or any part of this document be provided to unauthorized
person/companies without the written permission of Kaeser Compressor. Thank you for your cooperation.

1 Regarding this Document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 2
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Option codes .................................................................................................................... 4
2.3 Weight .............................................................................................................................. 5
2.4 Drive motor ....................................................................................................................... 6
2.5 Recommended oil ............................................................................................................ 6
2.6 Lubricating oil charge ....................................................................................................... 6
2.7 Temperature ..................................................................................................................... 7
2.8 Ambient and intake conditions ......................................................................................... 7
2.9 Filter maintenance indicator ............................................................................................. 8
2.10 Pressure display ............................................................................................................... 8
2.11 Sound pressure level/sound power level ......................................................................... 8
2.12 Power Supply ................................................................................................................... 8
2.13 Power supply specifications ............................................................................................. 9
2.14 Options ............................................................................................................................. 9
2.14.1 Oil level monitoring ............................................................................................. 9
2.14.2 Pressure switch .................................................................................................. 10
2.14.3 Speed monitor .................................................................................................... 10
2.14.4 Unloaded start valve (AFE) ................................................................................. 11
2.14.5 Temperature gauge switch ................................................................................. 11
2.14.6 Pressure sensor .................................................................................................. 12
2.14.7 Thermostat .......................................................................................................... 12
2.14.8 Filter pressure differential switch ........................................................................ 13
2.14.9 Check valve ........................................................................................................ 13
2.14.10 Auxiliary heating ................................................................................................. 13
2.14.11 Piped inlet ........................................................................................................... 14
2.14.12 Sound enclosure ................................................................................................. 14
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 15
3.2 Specified use .................................................................................................................... 15
3.3 Improper use .................................................................................................................... 15
3.4 User’s responsibilities ...................................................................................................... 16
3.4.1 Observe statutory and universally accepted regulations .................................... 16
3.4.2 Determining personnel ........................................................................................ 16
3.5 Dangers ............................................................................................................................ 16
3.5.1 Safely dealing with sources of danger ................................................................ 16
3.5.2 Safe machine operation ...................................................................................... 19
3.5.3 Organizational measures .................................................................................... 21
3.6 Danger areas ................................................................................................................... 21
3.7 Safety devices .................................................................................................................. 21
3.8 Safety signs ...................................................................................................................... 22
3.9 In emergency ................................................................................................................... 24
3.9.1 Correct fire fighting ............................................................................................. 24
3.9.2 Remove lubricating oil from the skin. .................................................................. 24
3.10 Environmental protection ................................................................................................. 24
Contents
Number: 9_9572 28 USE
Installation and Operating Manual Rotary lobe blower
HBPI pr i

3.11 Warranty ........................................................................................................................... 24
4 Design and Function
4.1 Machine ............................................................................................................................ 26
4.2 Blower block ..................................................................................................................... 27
4.3 Safety relief valve ............................................................................................................. 27
4.4 Safety devices .................................................................................................................. 28
4.5 Compensator .................................................................................................................... 28
4.6 Filter maintenance indicator ............................................................................................. 28
4.7 Pressure gauge ................................................................................................................ 28
4.8 Floating relay contacts ..................................................................................................... 29
4.9 Options ............................................................................................................................. 29
4.9.1 Oil level monitor .................................................................................................. 29
4.9.2 Pressure switch .................................................................................................. 29
4.9.3 Speed monitor .................................................................................................... 30
4.9.4 Unloaded start valve ........................................................................................... 30
4.9.5 Temperature gauge switch ................................................................................. 31
4.9.6 Pressure sensor .................................................................................................. 31
4.9.7 Thermostat .......................................................................................................... 32
4.9.8 Filter pressure differential switch ........................................................................ 32
4.9.9 Check valve ........................................................................................................ 33
4.9.10 Auxiliary heating ................................................................................................. 34
4.9.11 Outdoor installation ............................................................................................. 34
4.9.12 Piped inlet ........................................................................................................... 34
4.9.13 Sound enclosure ................................................................................................. 35
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 36
5.2 Installation conditions ....................................................................................................... 36
5.2.1 Determining location and clearances .................................................................. 36
5.2.2 Ensuring adequate ventilation ............................................................................ 37
5.3 Outdoor installation .......................................................................................................... 38
6 Installation
6.1 Ensuring safety ................................................................................................................ 39
6.2 Reporting transport damage ............................................................................................ 40
6.3 Anchoring the machine .................................................................................................... 40
6.4 Do not remove or change the adjusting screw of the pivoted motor base ....................... 40
6.5 Connecting the machine to the power supply .................................................................. 41
6.5.1 For frequency control .......................................................................................... 41
6.6 Installing the inlet silencer ................................................................................................ 43
6.7 Installing accessories at the T-piece ................................................................................ 43
6.8 Creating the compressed air connection .......................................................................... 44
6.9 Safety devices installed by the user ................................................................................. 45
6.10 Options ............................................................................................................................. 45
6.10.1 Connecting the oil level monitor .......................................................................... 45
6.10.2 Connecting the pressure switch .......................................................................... 45
6.10.3 Connecting the speed monitor ............................................................................ 45
6.10.4 Connecting the temperature gauge switch ......................................................... 46
6.10.5 Connecting the pressure sensor ......................................................................... 46
6.10.6 Connecting the thermostat .................................................................................. 46
6.10.7 Connecting the filter pressure differential switch ................................................ 46
6.10.8 Installing the check valve .................................................................................... 46
6.10.9 Installing the auxiliary heater .............................................................................. 47
6.10.10 Connecting the suction line ................................................................................. 47
6.10.11 Sound enclosure ................................................................................................. 48
Contents
ii
Installation and Operating Manual Rotary lobe blower
HBPI pr Number: 9_9572 28 USE

7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 57
7.2 Instructions to be observed before commissioning .......................................................... 58
7.3 Checking installation and operating conditions ................................................................ 58
7.4 Re-greasing the motor bearings ....................................................................................... 59
7.5 Checking the direction of rotation ..................................................................................... 59
7.5.1 Drive motor ......................................................................................................... 59
7.5.2 Ventilator fan (sound enclosure) ......................................................................... 59
8 Operation
8.1 Switching on and off ......................................................................................................... 60
8.1.1 Switching on ....................................................................................................... 60
8.1.2 Switching off ....................................................................................................... 60
8.2 Switching off in an emergency ......................................................................................... 60
8.3 Checking the ventilator fan function (sound enclosure) ................................................... 61
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 62
9.2 Faults ............................................................................................................................... 62
9.3 Options ............................................................................................................................. 63
9.3.1 Sound enclosure faults ....................................................................................... 63
9.3.2 Faulty pressure sensor ....................................................................................... 64
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 65
10.2 Maintenance schedule ..................................................................................................... 66
10.2.1 Logging maintenance work ................................................................................. 66
10.2.2 Regular maintenance tasks ................................................................................ 66
10.2.3 Regular service tasks ......................................................................................... 67
10.3 Sound enclosure .............................................................................................................. 68
10.4 Drive belt maintenance .................................................................................................... 68
10.5 Checking the oil level ....................................................................................................... 69
10.6 Replenishing lubricating oil .............................................................................................. 70
10.7 Changing the oil ............................................................................................................... 71
10.8 Air filter maintenance ....................................................................................................... 72
10.8.1 Filter maintenance indicator ................................................................................ 73
10.8.2 Filter pressure differential switch ........................................................................ 73
10.8.3 Changing the air filter .......................................................................................... 74
10.9 Machine cleaning ............................................................................................................. 74
10.10 Motor maintenance .......................................................................................................... 75
10.10.1 Drive motor bearings with re-greasing fittings .................................................... 75
10.10.2 Sound enclosure fan motor ................................................................................. 76
10.11 Testing the safety relief valve ........................................................................................... 76
10.12 Checking rotors for contamination ................................................................................... 77
10.13 Documenting maintenance and service work .................................................................. 78
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 79
11.2 Ordering consumable parts and operating fluids/materials .............................................. 79
11.3 Spare parts for service and repair .................................................................................... 79
11.3.1 HB 1300 PI pr ..................................................................................................... 79
11.3.2 HB 1600 PI pr ..................................................................................................... 82
11.4 KAESER AIR SERVICE ................................................................................................... 85
11.5 Completing the contamination declaration ....................................................................... 85
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 86
Contents
Number: 9_9572 28 USE
Installation and Operating Manual Rotary lobe blower
HBPI pr iii

12.2 Packing ............................................................................................................................ 86
12.3 Transport .......................................................................................................................... 87
12.3.1 Safety .................................................................................................................. 87
12.3.2 Transport with a forklift truck ............................................................................... 87
12.3.3 Transport with a crane ........................................................................................ 87
12.4 Storage ............................................................................................................................. 87
12.5 Disposal ........................................................................................................................... 88
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 89
13.2 Dimensional drawing ........................................................................................................ 92
13.3 Design diagrams .............................................................................................................. 96
13.4 Sound emission ................................................................................................................ 99
13.5 Drive motor electrical diagram ......................................................................................... 104
13.6 Electrical diagrams for options ......................................................................................... 114
13.6.1 Oil level monitoring – wiring diagram .................................................................. 114
13.6.2 Pressure switch wiring diagram .......................................................................... 117
13.6.3 Speed monitor wiring diagram ............................................................................ 117
13.6.4 Temperature gauge switch wiring diagram ......................................................... 117
13.6.5 Pressure sensor connections ............................................................................. 117
13.6.6 Thermostat wiring diagram ................................................................................. 118
13.6.7 Filter pressure differential switch wiring diagram ................................................ 118
13.6.8 Auxiliary heater wiring diagram ........................................................................... 118
13.6.9 Sound enclosure fan motor wiring plan .............................................................. 123
13.7 Project planning data ....................................................................................................... 123
Contents
iv
Installation and Operating Manual Rotary lobe blower
HBPI pr Number: 9_9572 28 USE

Fig. 1 Three-phase star (wye); 4 wire; center point solidly grounded ................................................... 9
Fig. 2 Three-phase star (wye); 3 wire; center point solidly grounded ................................................... 9
Fig. 3 Position of the safety signs at the machine ................................................................................ 22
Fig. 4 Safety sign location, electronically actuated options .................................................................. 22
Fig. 5 Safety sign location, standstill heater, Option H2 ....................................................................... 22
Fig. 6 Machine ...................................................................................................................................... 26
Fig. 7 Blower block ............................................................................................................................... 27
Fig. 8 Safety relief valve (blow-off valve) .............................................................................................. 27
Fig. 9 Compensator .............................................................................................................................. 28
Fig. 10 Location of the pressure gauge .................................................................................................. 28
Fig. 11 Pressure switch .......................................................................................................................... 29
Fig. 12 Unloaded start valve ................................................................................................................... 30
Fig. 13 Diagram of the unloaded start valve ........................................................................................... 30
Fig. 14 Location of the temperature gauge ............................................................................................ 31
Fig. 15 Pressure sensor ......................................................................................................................... 32
Fig. 16 Thermostat ................................................................................................................................. 32
Fig. 17 Filter pressure differential switch ................................................................................................ 32
Fig. 18 Pressure connection to the filter pressure differential switch ..................................................... 33
Fig. 19 Filter pressure differential switch function .................................................................................. 33
Fig. 20 Check valve ................................................................................................................................ 34
Fig. 21 Auxiliary heating ......................................................................................................................... 34
Fig. 22 Sound enclosure overview ......................................................................................................... 35
Fig. 23 Recommended machine placement and minimum dimensions [in.] .......................................... 37
Fig. 24 Pivoted motor base .................................................................................................................... 40
Fig. 25 Installing the inlet silencer .......................................................................................................... 43
Fig. 26 Installing the T-piece .................................................................................................................. 43
Fig. 27 Installing the check valve ........................................................................................................... 46
Fig. 28 Installing the auxiliary heater ...................................................................................................... 47
Fig. 29 Sound enclosure: Measuring points, connection diagram .......................................................... 48
Fig. 30 Connecting elements .................................................................................................................. 55
Fig. 31 Sound enclosure ........................................................................................................................ 68
Fig. 32 Drive belt maintenance ............................................................................................................... 68
Fig. 33 Checking the oil level ................................................................................................................. 70
Fig. 34 Replenishing lubricating oil ......................................................................................................... 71
Fig. 35 Changing the oil ......................................................................................................................... 72
Fig. 36 Filter maintenance indicator (machine without sound enclosure) .............................................. 73
Fig. 37 Filter maintenance indicator (machine with sound enclosure) ................................................... 73
Fig. 38 Changing the air filter ................................................................................................................. 74
Fig. 39 Motor maintenance ..................................................................................................................... 76
Fig. 40 Testing the safety relief valve ..................................................................................................... 76
Fig. 41 Pressure switch wiring diagram .................................................................................................. 117
Fig. 42 Speed monitor wiring diagram .................................................................................................... 117
Fig. 43 Temperature gauge switch wiring diagram ................................................................................ 117
Fig. 44 Pressure sensor connections ..................................................................................................... 117
Fig. 45 Thermostat wiring diagram ......................................................................................................... 118
Fig. 46 Filter pressure differential switch wiring diagram ....................................................................... 118
Fig. 47 Three-phase motor connection .................................................................................................. 123
Fig. 48 Single-phase motor connection .................................................................................................. 123
List of Illustrations
Number: 9_9572 28 USE
Installation and Operating Manual Rotary lobe blower
HBPI pr v

List of Illustrations
vi
Installation and Operating Manual Rotary lobe blower
HBPI pr Number: 9_9572 28 USE

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Option codes .............................................................................................................................. 4
Tab. 5 Weight without sound enclosure ................................................................................................ 5
Tab. 6 Weight with sound enclosure ..................................................................................................... 5
Tab. 7 Drive motor ................................................................................................................................. 6
Tab. 8 Recommended oil ...................................................................................................................... 6
Tab. 9 Lubricating oil charge ................................................................................................................. 7
Tab. 10 Temperature ............................................................................................................................... 7
Tab. 11 Ambient and intake conditions ................................................................................................... 7
Tab. 12 Filter maintenance indicator ....................................................................................................... 8
Tab. 13 Pressure display ......................................................................................................................... 8
Tab. 14 Oil level monitoring (Option C5) ................................................................................................. 9
Tab. 15 Pressure switch (option C9) ....................................................................................................... 10
Tab. 16 Speed monitoring sensor (Option C10) ...................................................................................... 10
Tab. 17 Speed monitoring device (Option C10) ...................................................................................... 10
Tab. 18 Setting of the speed monitor evaluation device (Option C10) .................................................... 11
Tab. 19 Unloaded start valve (AFE) ........................................................................................................ 11
Tab. 20 Temperature gauge switch (Option C13) ................................................................................... 11
Tab. 21 Pressure sensor (option C14) .................................................................................................... 12
Tab. 22 Thermostat (Option C19) ............................................................................................................ 12
Tab. 23 Filter pressure differential switch (Option F5) ............................................................................. 13
Tab. 24 Check valve (Option G1) ............................................................................................................ 13
Tab. 25 Auxiliary heating (Option H2) ..................................................................................................... 13
Tab. 26 Thermostatic auxiliary heating (Option H2) ................................................................................ 13
Tab. 27 Three phase power supply ......................................................................................................... 14
Tab. 28 Single phase power supply ........................................................................................................ 14
Tab. 29 Danger areas .............................................................................................................................. 21
Tab. 30 Safety signs ................................................................................................................................ 22
Tab. 31 Torques at the T-piece ............................................................................................................... 44
Tab. 32 Torques for customer pipeline .................................................................................................... 44
Tab. 33 Inlet compressor torques ............................................................................................................ 47
Tab. 34 Sound enclosure assembly (Option H12) ................................................................................... 49
Tab. 35 Recommissioning after storage/standstill ................................................................................... 58
Tab. 36 Installation conditions checklist .................................................................................................. 58
Tab. 37 Faults and remedies ................................................................................................................... 62
Tab. 38 Faults and remedies (option H12) .............................................................................................. 63
Tab. 39 Faults and remedies (Option C14) ............................................................................................. 64
Tab. 40 Regular maintenance tasks ........................................................................................................ 66
Tab. 41 Regular service tasks ................................................................................................................. 67
Tab. 42 Logged maintenance tasks ........................................................................................................ 78
Tab. 43 Consumable parts and operating fluids/materials ...................................................................... 79
Tab. 44 Blower block diagram (machine layout) ..................................................................................... 96
Tab. 45 Diagram legend .......................................................................................................................... 96
Tab. 46 Sound emission - legend ............................................................................................................ 99
List of Tables
Number: 9_9572 28 USE
Installation and Operating Manual Rotary lobe blower
HBPI pr vii

List of Tables
viii
Installation and Operating Manual Rotary lobe blower
HBPI pr Number: 9_9572 28 USE