KAESER BSD 40 User manual

Service Manual
Screw Compressor
BSD
9_5708 08 USE

Original instructions
/KKW/SBSD 1.02 en 01 SBA-SCHRAUBEN-SC
/KKW/SSC 1.04 01

1 Regarding this Document
1.1 Using the Document ......................................................................................................... 1
1.2 Further Documents .......................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and Identification ............................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Other instructions and symbols .......................................................................... 2
2Technical Data
2.1 Nameplate ........................................................................................................................ 3
2.2 Options ............................................................................................................................. 3
2.3 Weight .............................................................................................................................. 4
2.4 Temperature ..................................................................................................................... 4
2.5 Ambient Conditions .......................................................................................................... 4
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure ........................................................................................................................... 5
2.8 Delivery ............................................................................................................................ 6
2.9 Cooling Oil Recommendation .......................................................................................... 6
2.9.1 Basic Information ................................................................................................ 6
2.9.2 KAESER Lubricants ............................................................................................ 6
2.10 Cooling oil charge ............................................................................................................ 7
2.11 Motors and Power ............................................................................................................ 8
2.11.1 Drive motor ......................................................................................................... 8
2.11.2 Fan motor ........................................................................................................... 8
2.11.3 Fan motor ........................................................................................................... 9
2.12 Sound Pressure Level ...................................................................................................... 9
2.13 Power Supply ................................................................................................................... 9
2.14 Power Supply Specifications ............................................................................................ 10
2.15 Water-cooling ................................................................................................................... 11
2.15.1 Design data ......................................................................................................... 11
2.15.2 Cooling water quality .......................................................................................... 12
2.16 Heat recovery ................................................................................................................... 13
2.16.1 Prepared for external heat recovery ................................................................... 13
2.16.2 Internal heat recovery ......................................................................................... 13
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 16
3.2 Specified use .................................................................................................................... 16
3.3 Improper Use ................................................................................................................... 16
3.4 User's Responsibilities ..................................................................................................... 16
3.4.1 Observe statutory and universally accepted regulations .................................... 16
3.4.2 Qualified personnel ............................................................................................. 17
3.4.3 Adhere to Inspection Schedules and Accident Prevention Regulations. ............ 17
3.5 Dangers ............................................................................................................................ 17
3.5.1 Safely Dealing with Sources of Danger .............................................................. 18
3.5.2 Safe Machine Operation ..................................................................................... 20
3.5.3 Organizational Measures .................................................................................... 20
3.5.4 Danger Areas ...................................................................................................... 20
3.6 Safety Devices ................................................................................................................. 21
3.7 Safety Signs ..................................................................................................................... 21
3.8 Emergencies .................................................................................................................... 23
3.8.1 Correct fire fighting ............................................................................................. 23
3.8.2 Remove any cooling oil from your person .......................................................... 24
3.9 Warranty ........................................................................................................................... 24
3.10 Environmental Protection ................................................................................................. 24
Contents
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4 Design and Function
4.1 Enclosure ......................................................................................................................... 25
4.2 Functional Description of the Machine ............................................................................. 25
4.3 Floating relay contacts ..................................................................................................... 26
4.4 Options ............................................................................................................................. 27
4.4.1 Machine mountings ............................................................................................. 27
4.4.2 Cooling air filter mat ............................................................................................ 27
4.4.3 Water-cooling ...................................................................................................... 27
4.4.4 Heat recovery ..................................................................................................... 28
4.5 Operating modes and control modes ............................................................................... 29
4.5.1 Operating modes ................................................................................................ 29
4.5.2 Control modes .................................................................................................... 29
4.6 Safety Devices ................................................................................................................. 31
4.7 SIGMA CONTROL Keys and Indicators .......................................................................... 31
5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 34
5.2 Installation conditions ....................................................................................................... 34
5.2.1 Determining location and clearances .................................................................. 34
5.2.2 Ensure adequate ventilation. .............................................................................. 35
5.2.3 Exhaust duct design ........................................................................................... 35
5.3 Using the Compressor to Supply A Compressed Air System. ......................................... 36
6 Installation
6.1 Safety ............................................................................................................................... 37
6.2 Reporting Transport Damage ........................................................................................... 37
6.3 Making the Compressed Air Connection .......................................................................... 37
6.4 Making the Power Supply Connection ............................................................................. 38
6.5 Options ............................................................................................................................. 39
6.5.1 Anchoring the machine ....................................................................................... 39
6.5.2 Connecting the cooling water ............................................................................. 39
6.5.3 Connecting the heat recovery system ................................................................ 40
7 Initial Start-up
7.1 Safety ............................................................................................................................... 42
7.2 To be noted before commissioning .................................................................................. 42
7.3 Checking installation and operating conditions ................................................................ 43
7.4 Setting the overload protection cut-out ............................................................................ 44
7.5 Setting the motor overload protection switch ................................................................... 44
7.6 Filling cooling oil into the airend ....................................................................................... 44
7.7 Checking direction of rotation ........................................................................................... 45
7.8 Starting the machine for the first time .............................................................................. 46
7.9 Setting the Setpoint Pressure .......................................................................................... 46
7.10 Changing the display language ........................................................................................ 46
8 Operation
8.1 Switching On and Off ....................................................................................................... 48
8.1.1 Switching on ....................................................................................................... 48
8.1.2 Shutdown ............................................................................................................ 48
8.2 Switching Off in an Emergency and Switching On again ................................................. 49
8.3 Switching on and off from a remote control center ........................................................... 49
8.4 Switching on and off with the clock .................................................................................. 50
8.5 Acknowledging alarm and warning messages ................................................................. 51
9 Fault Recognition and Rectification
9.1 Basic Information ............................................................................................................. 53
9.2 Alarm messages (machine stop) ...................................................................................... 53
Contents
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9.3 Warning messages (yellow LED lights) ............................................................................ 56
9.4 Other Faults ..................................................................................................................... 60
10 Maintenance
10.1 Safety ............................................................................................................................... 62
10.2 Maintenance schedule ..................................................................................................... 63
10.2.1 Logging maintenance work ................................................................................. 63
10.2.2 Resetting maintenance interval counters ............................................................ 63
10.2.3 Regular maintenance tasks ................................................................................ 63
10.2.4 Cooling oil changing interval ............................................................................... 64
10.2.5 Regular service tasks ......................................................................................... 65
10.3 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 65
10.4 Cleaning or Replacing the Control Cabinet Filter Mats .................................................... 66
10.5 Cooler Maintenance ......................................................................................................... 67
10.6 Water-cooling Maintenance ............................................................................................. 68
10.7 Maintain the heat recovery system .................................................................................. 69
10.7.1 External heat recovery system ........................................................................... 69
10.7.2 Internal heat recovery ......................................................................................... 69
10.8 Air Filter Maintenance ...................................................................................................... 69
10.9 Motor Maintenance .......................................................................................................... 70
10.10 Checking the Coupling ..................................................................................................... 71
10.11 Checking the Safety Relief Valve ..................................................................................... 72
10.12 Checking the Overheating Safety Shutdown Function ..................................................... 73
10.13 Checking the Cooling Oil Level ........................................................................................ 73
10.14 Venting the machine (depressurizing) .............................................................................. 74
10.15 Topping up the Cooling Oil ............................................................................................... 76
10.15.1 Venting the Machine (depressurizing) ................................................................ 76
10.15.2 Top up with cooling oil and test run .................................................................... 77
10.16 Changing the cooling oil ................................................................................................... 78
10.17 Changing the Oil Filter ..................................................................................................... 83
10.18 Changing the Oil Separator Cartridge .............................................................................. 84
10.19 Document maintenance and service work. ...................................................................... 87
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 88
11.2 Ordering consumable parts and operating fluids/materials .............................................. 88
11.3 KAESER AIR SERVICE .................................................................................................. 88
11.4 Service Addresses ........................................................................................................... 89
11.5 Spare Parts for Service and Repair ................................................................................. 89
12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation .................................................................................................. 94
12.2 Packing ............................................................................................................................ 94
12.3 Storage ............................................................................................................................. 94
12.4 Transporting ..................................................................................................................... 95
12.4.1 Safety .................................................................................................................. 95
12.4.2 Transporting with a forklift ................................................................................... 95
12.4.3 Transporting with a crane ................................................................................... 95
12.5 Disposal ........................................................................................................................... 96
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 97
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 103
13.3 Dimensional Drawing ....................................................................................................... 109
13.4 Electrical Diagram ............................................................................................................ 113
Contents
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Contents
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Fig. 1 Maximum relative humidity ......................................................................................................... 5
Fig. 2 Location of safety signs .............................................................................................................. 22
Fig. 3 Enclosure overview .................................................................................................................... 25
Fig. 4 Machine layout ........................................................................................................................... 26
Fig. 5 Machine mountings .................................................................................................................... 27
Fig. 6 Cooling air filter mat (option K3) ................................................................................................. 27
Fig. 7 Water-cooling (option K2) ........................................................................................................... 28
Fig. 8 Internal heat recovery (option W2/W3) ....................................................................................... 29
Fig. 9 Keys ........................................................................................................................................... 31
Fig. 10 Indicators .................................................................................................................................... 32
Fig. 11 Recommended machine placement and dimensions [mm] ........................................................ 35
Fig. 12 Compressed air connection ........................................................................................................ 38
Fig. 13 Connecting the cooling water ..................................................................................................... 39
Fig. 14 Connecting the heat recovery system ........................................................................................ 41
Fig. 15 Inlet valve filling port ................................................................................................................... 45
Fig. 16 Coupling ..................................................................................................................................... 45
Fig. 17 Label: Changing the display language ....................................................................................... 47
Fig. 18 Switching on and off ................................................................................................................... 48
Fig. 19 Switching off in an emergency ................................................................................................... 49
Fig. 20 Switching on and off from a remote control center ..................................................................... 50
Fig. 21 Switching on and off with the clock ............................................................................................ 51
Fig. 22 Acknowledging messages .......................................................................................................... 52
Fig. 23 Cooling air filter mat ................................................................................................................... 66
Fig. 24 Control cabinet ventilation grill ................................................................................................... 67
Fig. 25 Cleaning the cooler .................................................................................................................... 68
Fig. 26 Air filter maintenance .................................................................................................................. 70
Fig. 27 Drive motor maintenance ........................................................................................................... 71
Fig. 28 Checking the coupling ................................................................................................................ 72
Fig. 29 Checking the cooling oil level ..................................................................................................... 74
Fig. 30 Venting the machine ................................................................................................................... 75
Fig. 31 Topping up the Cooling Oil ......................................................................................................... 76
Fig. 32 Changing the cooling oil, oil separator tank ............................................................................... 79
Fig. 33 Changing the cooling oil, oil cooler ............................................................................................. 80
Fig. 34 Changing the cooling oil, airend ................................................................................................. 81
Fig. 35 Changing the cooling oil, oil tank ................................................................................................ 82
Fig. 36 Changing the cooling oil, heat recovery system ......................................................................... 83
Fig. 37 Changing the oil filter .................................................................................................................. 84
Fig. 38 Changing the Oil Separator Cartridge ........................................................................................ 85
Fig. 39 Transporting with a forklift .......................................................................................................... 95
Fig. 40 Transporting with a crane ........................................................................................................... 96
List of Illustrations
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List of Illustrations
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Tab. 1 The levels of danger and their meaning ..................................................................................... 1
Tab. 2 Nameplate .................................................................................................................................. 3
Tab. 3 Options ....................................................................................................................................... 3
Tab. 4 Machine weight .......................................................................................................................... 4
Tab. 5 Temperature ............................................................................................................................... 4
Tab. 6 Ambient Conditions .................................................................................................................... 4
Tab. 7 Ventilation ................................................................................................................................... 5
Tab. 8 Safety relief valve setting .......................................................................................................... 5
Tab. 9 Delivery ..................................................................................................................................... 6
Tab. 10 Cooling oil charge (Option K1) ................................................................................................... 7
Tab. 11 Cooling oil charge (Option K2) ................................................................................................... 7
Tab. 12 Cooling oil charge (Option W1) .................................................................................................. 8
Tab. 13 Cooling oil charge (Option W2) .................................................................................................. 8
Tab. 14 Cooling oil charge (Option W3) .................................................................................................. 8
Tab. 15 Drive motor ................................................................................................................................. 8
Tab. 16 Fan motor (option K1) ................................................................................................................ 8
Tab. 17 Fan motor (option K2) ................................................................................................................ 9
Tab. 18 Sound pressure level .................................................................................................................. 9
Tab. 19 Supply 208V/3/60Hz ................................................................................................................... 10
Tab. 20 Connection details 230V/3/60Hz ................................................................................................ 10
Tab. 21 Connection details 380V/3/60Hz ................................................................................................ 11
Tab. 22 Connection details 460V/3/60Hz ................................................................................................ 11
Tab. 23 Supply 575V/3/60Hz ................................................................................................................... 11
Tab. 24 Cooling water temperature (ΔT=20°F) ....................................................................................... 11
Tab. 25 Cooling water temperature (ΔT=50°F) ....................................................................................... 12
Tab. 26 Cooler specification (option K2) ................................................................................................. 12
Tab. 27 Cooling water quality .................................................................................................................. 12
Tab. 28 Heat capacity (option W1) .......................................................................................................... 13
Tab. 29 Water quality specification .......................................................................................................... 14
Tab. 30 Heat exchanger specification (option W2/W3) ........................................................................... 14
Tab. 31 Heat capacity (option W2/W3) .................................................................................................... 15
Tab. 32 Flow rate / pressure loss (option W2) ......................................................................................... 15
Tab. 33 Flow rate / pressure loss (option W3) ......................................................................................... 15
Tab. 34 Danger Areas ............................................................................................................................. 21
Tab. 35 Safety Signs ............................................................................................................................... 22
Tab. 36 Energy-efficient control modes ................................................................................................... 30
Tab. 37 Operating modes under MODULATING control ......................................................................... 30
Tab. 38 Keys ........................................................................................................................................... 31
Tab. 39 Indicators .................................................................................................................................... 32
Tab. 40 Re-commissioning after storage ................................................................................................. 43
Tab. 41 Installation and operating conditions checklist ........................................................................... 43
Tab. 42 Machine identification ................................................................................................................. 50
Tab. 43 Remote control identification ...................................................................................................... 50
Tab. 44 Machine identification ................................................................................................................. 51
Tab. 45 Alarm messages and measures ................................................................................................. 53
Tab. 46 Warning messages ..................................................................................................................... 56
Tab. 47 Other faults and actions ............................................................................................................. 60
Tab. 48 Regular maintenance tasks ........................................................................................................ 63
Tab. 49 Oil change intervals lubricants ................................................................................................... 64
Tab. 50 Regular service tasks ................................................................................................................. 65
Tab. 51 Logged maintenance tasks ........................................................................................................ 87
Tab. 52 Consumable parts ...................................................................................................................... 88
List of Tables
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List of Tables
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1 Regarding this Document
1.1 Using the Document
The service manual is part of the machine.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are entered in the manual.
➤ Enter details from the machine nameplate and individual items of equipment in the table in chap‐
ter 2.
1.2 Further Documents
Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
■ certificate of acceptance / operating instructions for the pressure vessel,
■ operating instructions (for SIGMA CONTROL).
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documentation
should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and Identification
1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
DANGER
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruction.
➤ The measures required to protect yourself from danger are shown here.
➤ Always read and comply with warning instructions.
Signal word Meaning Consequences of non-observance
DANGER Warns of an imminent threat of danger Death or serious injury may result
1 Regarding this Document
1.1 Using the Document
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BSD 1

Signal word Meaning Consequences of non-observance
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐
tion
Light injuries or material damage are possible
Tab. 1 The levels of danger and their meaning
1.4.2 Other instructions and symbols
This symbol refers to particularly 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.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This bullet 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 that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used in
this service manual are explained in chapter 2.2 .
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protection.
Further information Here, your attention is drawn to further topics.
1 Regarding this Document
1.4 Symbols and Identification
2
Service Manual Screw Compressor
BSD 9_5708 08 USE
Option H1

2 Technical Data
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine:
■ above the cooler
or
■ on the rear of the machine.
➤ Enter data from the nameplate here as reference:
Characteristic Value
Model
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQUIPMENT NUMBER
Tab. 2 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference.
Option Option code Available?
Modulating control C1
SIGMA CONTROL C3
Adjustable machine mountings H1
Air-cooling K1
Water cooling K2
Cooling-air filter mat K3
Transformer power supply for refrigeration dryer T2
Prepared for heat recovery W1
2 Technical Data
2.1 Nameplate
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BSD 3

Option Option code Available?
Heat recovery ΔT=45 K W2
Heat recovery ΔT=55 K W3
Tab. 3 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equipment
fitted.
BSD 40 BSD 50 BSD 60
Weight [lb] 2270 2350 2540
Tab. 4 Machine weight
2.4 Temperature
BSD 40 BSD 50 BSD 60
Minimum cut-in tempera‐
ture [°F]
40 40 40
Typical airend discharge
temperature during opera‐
tion [°F]
167–200 167–200 167–200
Maximum. airend dis‐
charge temp. (automatic
shut-down) [°F]
230 230 230
Tab. 5 Temperature
2.5 Ambient Conditions
BSD 40 BSD 50 BSD 60
Maximum elevation [ft.] 3000 3000 3000
Permissible ambient tem‐
perature [°F]
40–115 40–115 40–115
Cooling air temperature
[°F]
40–115 40–115 40–115
Inlet air temperature [°F] 40–115 40–115 40–115
Maximum relative humidi‐
ty of inlet air
see figure 1 see figure 1 see figure 1
* Higher elevation permissible only after consultation with the manufacturer
Tab. 6 Ambient Conditions
2 Technical Data
2.3 Weight
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Fig. 1 Maximum relative humidity
TInlet air temperature [°F]
HMaximum relative humidity of inlet air [%]
2.6 Ventilation
The values given are minimum guide values.
BSD 40 BSD 50 BSD 60
Inlet aperture Z see fig‐
ure 11 [sq.ft.]
8.6/2.2* 10.8/2.2* 12.9/2.2*
Forced ventilation with ex‐
haust fan:
Flow rate [cfm] at 0.4 in wc
6474
942*
7946
1177*
9712
1471*
Exhaust duct:
Dimensions [in]
27 1/2 x 27 1/2 27 1/2 x 27 1/2 27 1/2 x 27 1/2
* Option K2
Tab. 7 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
Safety relief valve blow-off setting [psig]:
Maximum working pres‐
sure [psig]
BSD 40 BSD 50 BSD 60
125 155 155 155
175 230 230 230
217 — 232 232
Tab. 8 Safety relief valve setting
2 Technical Data
2.6 Ventilation
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2.8 Delivery
FAD [cfm]
Maximum working pres‐
sure [psig]
BSD 40 BSD 50 BSD 60
125 193 236 288
175 157 190 230
217 — 154 185
Tab. 9 Delivery
2.9 Cooling Oil Recommendation
A sticker showing the type of oil filled is located near the oil separator filler.
Information for ordering cooling oil can be found in chapter 13.4.
2.9.1 Basic Information
Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in
compressor cooling oils. These deposits block the flow of lubricant and cause excessive wear and
failure of moving parts. Contamination of the lubricant can allow the formation of acids, causing ex‐
tensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors do much more than lubricate. During the compression process, it
acts as a sealant in the airend which is important for maximum efficiency. The lubricant also absorbs
much of the heat of compression to cool the airend and reduce the temperature of the compressed
air. It’s not enough that a compressor cooling oil lubricates well, it must stand up to the heat, pressure
and contaminants that are present in every air compressor.
2.9.2 KAESER Lubricants
KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do
not re-use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐
pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire-
resistant fluid. It has a flash point above 460 °F. Since the user has total control over the conditions
of the compressor lubricant, he assumes total responsibility for its safe usage.
Material Safety Data Sheets are available for each lubricant from your authorized KAESER Service
representative.
Regardless of the lubricant selected, the KAESER SIGMA lubricants will separate readily from water.
If condensate occurs it can easily be removed. Let the compressor sit so that any water can drain
back to the separator tank and separate to the bottom. See chapter 10.16 proper draining procedure.
KAESER has several lubricants available that are specially formulated to match these demands. They
feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long life.
M-SERIES:
■ M-Series SIGMA compressor cooling oils are semi-synthetic lubricants.
■ M-Series SIGMA compressor cooling oils are the highest quality petroleum lubricants. M–460 is
specially blended to provide reliable performance in KAESER screw compressors.
2 Technical Data
2.8 Delivery
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S-SERIES:
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
■ S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐
bricants. These ”synthetic” lubricants begin as high quality petroleum feed stock. They are then
refined, processed and purified into fluids with very consistent molecular structure. These oils are
carefully blended to produce extremely consistant lubricants with superior properties. SIGMA
synthetic lubricants feature all the advantages of both PAO and diester fluids.
■ S–460 lubricant is recommended for compressors operating in ambient temperatures between
40 °F and 105 °F.
Specialty KAESER LUBRICANTS:
■ S–680 lubricant may be used when ambient temperatures are always between 70 °F and 105 °F.
■ FG–460 synthetic hydrocarbon based food grade lubricant is designed for use in rotary screw
compressors in the application where incidental food contact may occur with the discharge air.
This lubricant meets the requirements of the FDA Regulation 21 CFR §178.3570 and is USDA H–
1 approved and NSF certified. FG–460 is approved for canning, food packing, meat and poultry
processing and other applications where incidental food contact may occur.
2.10 Cooling oil charge
The required cooling oil charge depends on the optional heat recovery system. For machines with
options W1, W2, or W3, the volume required additionally for the heat recovery must be added to the
charge.
Air-cooling
BSD 40 BSD 50 BSD 60
Fluid volume* [gal] 6.9 6.9 6.9
Topping up volume [quart]
(minimum–maximum)
4.4 4.4 4.4
* Plus the oil volume of the heat recovery system.
Tab. 10 Cooling oil charge (Option K1)
Water cooling
BSD 40 BSD 50 BSD 60
Fluid volume [gal] 8.2 8.2 8.2
Fluid quantity* [gal]
for options W1, W2, or W3
5.3 5.3 5.3
Topping up volume [quart]
(minimum–maximum)
4.4 4.4 4.4
* Plus the oil volume of the heat recovery system.
Tab. 11 Cooling oil charge (Option K2)
2 Technical Data
2.10 Cooling oil charge
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Service Manual Screw Compressor
BSD 7
Option K1
Option K2

Heat recovery
The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines:
BSD 40 BSD 50 BSD 60
Additional charge vol‐
ume [quart]*
* Enter the volume required by your heat recovery system.
Tab. 12 Cooling oil charge (Option W1)
BSD 40 BSD 50 BSD 60
Additional charge vol‐
ume [quart]
4.4 4.4 4.4
Tab. 13 Cooling oil charge (Option W2)
BSD 40 BSD 50 BSD 60
Additional charge vol‐
ume [quart]
1.6 1.6 1.6
Tab. 14 Cooling oil charge (Option W3)
2.11 Motors and Power
2.11.1 Drive motor
BSD 40 BSD 50 BSD 60
Rated power [hp] 40 50 60
Rated speed [rpm] 3565 3565 3570
Enclosure protection TEFC TEFC TEFC
Motor bearing greasing in‐
terval [h]
2000 2000 2000
Grease requirement, each
bearing [g]**
** Transfer data from the motor nameplate to the table for reference purposes.
h = operating hours
Tab. 15 Drive motor
2.11.2 Option K1
Fan motor
BSD 40 BSD 50 BSD 60
Rated power [hp] 1.2 1.2 1.2
h = operating hours
2 Technical Data
2.11 Motors and Power
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Option W1/W2/W3
Option W1
Option W2
Option W3

BSD 40 BSD 50 BSD 60
Rated speed [rpm] 1120 1120 1120
Enclosure protection TEFC TEFC TEFC
h = operating hours
Tab. 16 Fan motor (option K1)
2.11.3 Option K2
Fan motor
BSD 40 BSD 50 BSD 60
Rated power [hp] 0.13 0.13 0.13
Rated speed [rpm] 2700 2700 2700
Enclosure protection TEFC TEFC TEFC
Tab. 17 Fan motor (option K2)
2.12 Sound Pressure Level
Operational state
■ Nominal volume flow
■ Nominal pressure
Measurement conditions
■ Free-field measurement to CAGI/PNEUROP PN8 NTC 2.3
■ Measurement distance: 1 m
BSD 40 BSD 50 BSD 60
Sound pressure lev‐
el [dB (A)]
68 69 71
Tab. 18 Sound pressure level
2.13 Power Supply
Basic requirements
The machine is designed for an electrical supply according to National Electric Code (NEC) NEC–
670, particularly NFPA 79, edition 2007, section 4.3. In the absence of any user-specified alternatives,
the limits given in these standards must be adhered to. Consult manufacturer for any other specific
power supply.
Further requirements
Demands on a three-phase supply for a machine with the following equipment:
■ Refrigeration dryer powered from a transformer
2 Technical Data
2.12 Sound Pressure Level
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Service Manual Screw Compressor
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This machine may only be supplied from a grounded TN or TT three-phase supply in which the neutral
point is grounded.
The machine may not be connected to a three-phase supply in which one of the phases is grounded,
as this can lead to dangerous voltage surges.
Connection to an IT network is not permitted without further measures being taken (ground leak
detection, specially designed frequency converter, etc.).
Further information The wiring diagram in chapter 13.4 contains further details of the power supply connection.
2.14 Power Supply Specifications
The following multi-strand copper core wires are given according to 2008 NEC 310.15, Table 310.16
for 40 °C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should be
checked and adjusted according to 2008 NEC 110.14©, 220.3,310.15, Table 310.16, 430.6, 430.22,
430.24 and other local codes.
Dual element time delay fuses are selected according to 2008 NEC 240.6,430.52and tables 430.52,
430.248 and 430.250.
We strongly suggest using a separate copper conductor for the equipment GROUNDING. NEC Ta‐
ble 250.122 will point out the ”minimum size”, however, we recommend a ground conductor the same
size as the power leads, if local codes allow.
Rated power supply 208V ±10%, 3-ph, 60Hz
BSD 40 BSD 50 BSD 60
Pre-fuse [A] 175/150* 200 —
Supply 4x AWG2/0** 4x AWG4/0** —
Consumption [A] 121 146 —
** 75 °C
Tab. 19 Supply 208V/3/60Hz
Rated power supply 230V±10%/3/60Hz
BSD 40 BSD 50 BSD 60
Pre-fuse [A] 150 175 —
Supply 4x AWG2/0**/
AWG1/0** *
4x AWG3/0** —
Consumption [A] 108/105* 131/128* —/—*
* Option K2
** 75 °C
Tab. 20 Connection details 230V/3/60Hz
2 Technical Data
2.14 Power Supply Specifications
10
Service Manual Screw Compressor
BSD 9_5708 08 USE