KAESER KOMPRESSOREN OMEGA 4 B User instructions

Assembly and operating manual
Blower block
OMEGA 4 B
Number: 9_9533 23 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

/KKW/BOMBB 2.03 en SBA-OMEGA_4_B
20150401 133922

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 Warning notices .................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 3
2.2 Option codes .................................................................................................................... 3
2.3 Weight .............................................................................................................................. 4
2.4 Pressure ........................................................................................................................... 4
2.4.1 Operating mode: Vacuum ................................................................................... 4
2.4.2 Sealing, inside: Vacuum seal .............................................................................. 5
2.4.3 Sealing, inside: Vacuum and gauge pressure sealing ........................................ 5
2.5 Flow rate .......................................................................................................................... 5
2.6 Power and speeds ........................................................................................................... 5
2.7 Drive shaft load ................................................................................................................ 6
2.8 Connection dimensions .................................................................................................... 6
2.9 Temperature ..................................................................................................................... 6
2.10 Recommended oil ............................................................................................................ 6
2.11 Lubricating oil charge ....................................................................................................... 7
2.12 Ambient and intake conditions ......................................................................................... 7
2.13 Noise emission ................................................................................................................. 7
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 9
3.2 Intended use .................................................................................................................... 9
3.3 Improper use .................................................................................................................... 9
3.4 User's responsibilities ....................................................................................................... 10
3.4.1 To be noted when integrating in a machine ........................................................ 10
3.4.2 Observe statutory and universally accepted regulations .................................... 10
3.4.3 Determining personnel ........................................................................................ 10
3.5 Dangers ............................................................................................................................ 10
3.5.1 Safely dealing with sources of danger ................................................................ 10
3.5.2 Organisational measures .................................................................................... 12
3.5.3 Safe operation of the blower block ..................................................................... 12
3.6 Danger areas ................................................................................................................... 14
3.7 Safety signs ...................................................................................................................... 14
3.8 In emergency ................................................................................................................... 15
3.8.1 Correct fire fighting ............................................................................................. 15
3.8.2 Remove lubricating oil from the skin. .................................................................. 16
3.9 Environment protection .................................................................................................... 16
3.10 Warranty ........................................................................................................................... 16
4 Design and Function
4.1 Function ........................................................................................................................... 17
4.2 Options ............................................................................................................................. 17
4.2.1 Flow direction: vertical ........................................................................................ 18
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 19
5.2 Determining the location .................................................................................................. 19
Contents
Number: 9_9533 23 E
Assembly and operating manual Blower block
OMEGA 4 B i

6 Installation
6.1 Ensuring safety ................................................................................................................ 20
6.2 Reporting transport damage ............................................................................................ 20
6.3 Installation options ........................................................................................................... 20
6.4 Installing the blower block ................................................................................................ 21
6.5 Installing the drive ............................................................................................................ 22
6.6 Safety devices installed by the user ................................................................................. 23
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 25
7.2 Checking installation and operating conditions ................................................................ 25
7.3 Instructions to be observed before commissioning or re-commissioning ......................... 26
7.4 Checking direction of rotation ........................................................................................... 26
8 Operation
8.1 Switching on and off ......................................................................................................... 27
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 28
9.2 Alarms .............................................................................................................................. 28
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 30
10.2 Maintenance schedule ..................................................................................................... 30
10.2.1 Logging maintenance work ................................................................................. 30
10.2.2 Regular maintenance tasks ................................................................................ 30
10.2.3 Regular service tasks ......................................................................................... 31
10.3 Checking the oil level ....................................................................................................... 31
10.4 Replenishing lubricating oil .............................................................................................. 32
10.5 Changing the oil ............................................................................................................... 33
10.6 Checking rotors for contamination ................................................................................... 34
10.7 Documenting maintenance and service work .................................................................. 35
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 36
11.2 Ordering spares and operating fluids/materials ............................................................... 36
11.3 KAESER AIR SERVICE .................................................................................................. 36
11.4 Service Addresses ........................................................................................................... 36
11.5 Declaration of Contamination ........................................................................................... 37
11.5.1 Shipment of the blower block .............................................................................. 37
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 38
12.2 Packing ............................................................................................................................ 38
12.3 Transport .......................................................................................................................... 38
12.3.1 Safety .................................................................................................................. 38
12.3.2 Transporting with a crane ................................................................................... 38
12.4 Storage ............................................................................................................................. 39
12.5 Disposal ........................................................................................................................... 40
13 Annex
13.1 Dimensional drawing ........................................................................................................ 41
13.2 Design diagrams .............................................................................................................. 44
13.2.1 Operating mode: Vacuum ................................................................................... 44
13.2.2 Sealing, inside: Vacuum and gauge pressure sealing ........................................ 47
13.3 Declaration concerning contamination ............................................................................. 50
Contents
ii
Assembly and operating manual Blower block
OMEGA 4 B Number: 9_9533 23 E

Fig. 1 Location of safety signs .............................................................................................................. 15
Fig. 2 Principle of compression ............................................................................................................ 17
Fig. 3 Block overview – flow direction: vertical ..................................................................................... 18
Fig. 4 Permissible angle deviation: ....................................................................................................... 21
Fig. 5 Checking the oil level ................................................................................................................. 32
Fig. 6 Replenishing lubricating oil ......................................................................................................... 32
Fig. 7 Changing the oil ......................................................................................................................... 33
Fig. 8 Transport with a crane ................................................................................................................ 39
List of Illustrations
Number: 9_9533 23 E
Assembly and operating manual Blower block
OMEGA 4 B iii

List of Illustrations
iv
Assembly and operating manual Blower block
OMEGA 4 B Number: 9_9533 23 E

Tab. 1 Danger levels and their definition ............................................................................................... 2
Tab. 2 Nameplate .................................................................................................................................. 3
Tab. 3 Option codes .............................................................................................................................. 3
Tab. 4 Weight ........................................................................................................................................ 4
Tab. 5 Pressure ..................................................................................................................................... 4
Tab. 6 Theoretical flow rate at maximum speed .................................................................................... 5
Tab. 7 Power requirement ..................................................................................................................... 5
Tab. 8 Rotational speeds ....................................................................................................................... 5
Tab. 9 Drive shaft load .......................................................................................................................... 6
Tab. 10 Connection dimensions .............................................................................................................. 6
Tab. 11 Block discharge temperature ...................................................................................................... 6
Tab. 12 Temperature difference .............................................................................................................. 6
Tab. 13 Recommended oil ...................................................................................................................... 7
Tab. 14 Lubricating oil charge ................................................................................................................. 7
Tab. 15 Ambient conditions ..................................................................................................................... 7
Tab. 16 Permissible intake temperature .................................................................................................. 7
Tab. 17 Sound pressure level .................................................................................................................. 8
Tab. 18 Sound power level ...................................................................................................................... 8
Tab. 19 Danger areas ............................................................................................................................. 14
Tab. 20 Safety signs ................................................................................................................................ 15
Tab. 21 Installation options ...................................................................................................................... 21
Tab. 22 Installation conditions checklist .................................................................................................. 25
Tab. 23 Re-commissioning after storage ................................................................................................. 26
Tab. 24 Other faults and actions. ............................................................................................................ 28
Tab. 25 Regular maintenance tasks ........................................................................................................ 31
Tab. 26 Regular service tasks ................................................................................................................. 31
Tab. 27 Logged maintenance tasks ........................................................................................................ 35
Tab. 28 Ordering spares and operating fluids/materials .......................................................................... 36
Tab. 29 Legend, dimensional drawing ..................................................................................................... 41
Tab. 30 Legend, vacuum diagrams ......................................................................................................... 44
Tab. 31 Legend, gauge pressure diagrams ............................................................................................. 47
List of Tables
Number: 9_9533 23 E
Assembly and operating manual Blower block
OMEGA 4 B v

List of Tables
vi
Assembly and operating manual Blower block
OMEGA 4 B Number: 9_9533 23 E

1 Regarding this document
1.1 Using this document
This document, hereafter called the service manual, contains important information about all life
phases of the machine.
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Further documents included with this operating manual to assist in safe and sure operation of the
block are:
■ Installation declaration in accordance with applicable directives.
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.4 Symbols and labels
1.4.1 Warning notices
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
1. DANGER!
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the
warning.
➤ The measures required to protect yourself from danger are shown here.
1 Regarding this document
1.1 Using this document
Number: 9_9533 23 E
Assembly and operating manual Blower block
OMEGA 4 B 1

2. Always read and comply with warning instructions.
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent
danger
May result in death or severe injury
CAUTION Warns of a potentially dangerous
situation
May result in moderate physical injury or damage
to objects
Tab. 1 Danger levels and their definition
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Damage warnings have only one danger level identified with this signal term:
■ NOTE
1. NOTICE!
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
2. Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols
This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
➤ This symbol is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information related to just one option is marked with a symbol (e.g. B7 indicates that this sec‐
tion refers only to blower blocks with a drive shaft left). Option codes used in this service man‐
ual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is identified in the help text ...
➤ ... as is a remedy.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.
1 Regarding this document
1.4 Symbols and labels
2
Assembly and operating manual Blower block
OMEGA 4 B Number: 9_9533 23 E
Option B7