Kaishan KRSL Series User manual

PN: 96002018000001
Release: August 2022, Version: B
(USA)
Kaishan
Rotary Screw
Air Compressor
KRSL Series
Instruction
Manual
Direct Drive

KRSL series Page 2
TABLE OF CONTENTS
Safety Information ...................................................................................................... 4
1.1 SAFETY ALERT SYMBOLS................................................................................................................ 4
1.2 SAFETY PRECAUTIONS ................................................................................................................... 5
1.3 PRESSURE ......................................................................................................................................... 5
1.4 FIRE AND EXPLOSION .................................................................................................................... 5
1.5 MOVING PARTS ................................................................................................................................ 6
1.6 HOT SURFACES ................................................................................................................................ 6
1.7 PROPER COMPRESSED AIR APPLICATIONS................................................................................ 6
1.8 ELECTRICAL SHOCK ....................................................................................................................... 6
General Information.................................................................................................... 8
2.1 INTRODUCTION ............................................................................................................................... 8
2.2 THE COMPRESSION CYCLE............................................................................................................ 9
2.3 MOTOR............................................................................................................................................... 9
2.4 COMPRESSOR LUBRICATION AND COOLING SYSTEM............................................................ 10
2.5 COMPRESSOR DISCHARGE SYSTEM........................................................................................... 10
2.6 AIREND, INLETVALVE AND FILTRATION SYSTEM .................................................................... 12
Fluid Information ...................................................................................................... 13
3.1 FLUID GUIDE ................................................................................................................................. 13
3.2 FLUID CHANGE RECOMMENDATIONS ...................................................................................... 13
Installation................................................................................................................ 14
4.1 COMPRESSOR MOUNTING, SUPPORT AND LOCATION........................................................... 15
4.2 VENTILATION AND COOLING ...................................................................................................... 15
4.3 PIPING CONNECTION ................................................................................................................... 16
4.4 FLUID LEVEL INSPECTION .......................................................................................................... 17
4.5 ELECTRICAL ................................................................................................................................... 18
4.6 MOTOR ROTATION INSPECTION ................................................................................................. 18
4.7 FAN ROTATION INSPECTION ....................................................................................................... 19

Page 3KRSL series
Compressor Controller Operation.............................................................................. 20
5.1 BASIC OPERATION......................................................................................................................... 20
5.2. PROGRAM STRUCTURE ............................................................................................................... 23
5.3. TECHNICAL DATA......................................................................................................................... 32
5.4. THROUBLESHOOTING ................................................................................................................ 33
Servicing ................................................................................................................... 33
6.1 FLUID CHANGE............................................................................................................................. 34
6.2 AIR FILTER ...................................................................................................................................... 34
6.3 FLUID FILTER................................................................................................................................. 35
6.4 AIR/OIL SEPARATOR...................................................................................................................... 35
6.5 FLUID SAMPLING PROCEDURE.................................................................................................. 35
6.6 MAINTENANCE SCHEDULE.......................................................................................................... 36
Troubleshooting Guide.............................................................................................. 36
Standard Terms and Conditions................................................................................. 40
Contact Information .................................................................................................. 43

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Safety Information
Thank you for choosing the KRSL Series Compressor. Please read this instruction manual
carefully before using the compressor. This manual must be kept in the safe place for future
reference. Kaishan USA authorized distributors provide maintenance service for KRSL series
rotary screw compressors. A certified technician is required to ensure that compressor
maintenance is safely handled. By following the instructions in this manual, the user will
minimize possibility of an accident throughout the useful life of this equipment.
1.1 SAFETY ALERT SYMBOLS
Key hazards are used throughout this manual. The level of hazards seriousness is symbolized as
follows:
This symbol identifies immediate
hazards which will result in severe
personal injury, death or substantial
property damage.
This symbol identifies hazards or
unsafe practices which could
result in personal injury, death or
substantial property damage.
This symbol identifies immediate
electrical hazards which will result
in severe personal injury, death or
substantial properly damage.
This symbol identifies hazards or
unsafe practices which could
result in personal injury or
substantial property damage.
This symbol identifies immediate
hot surface hazards which will
result in severe personal injury.
NOTICE
Identifies important installation,
operation or maintenance
information which is not hazard
related.

Page 5KRSL series
1.2 SAFETY PRECAUTIONS
This manual describes the safety precautions, structure and functions of all systems and
components, as well as the operation and maintenance methods for the KRSL series rotary screw
air compressors. The owner and operator shall read this manual carefully. Only after thorough
understanding should the machine be operated for the first time. This manual gives you a general
description of the mechanical and electrical systems and maintenance. However, if you have any
questions about operating and maintenance of the compressor; please contact your authorized
distributor or our service department personnel.
Do not modify the compressor and/or controls in any way except with written factory approval.
While not specifically applicable to all types of compressors with all types of main movers, most
of the precautionary statements contained herein are applicable to most compressors and the
concepts behind these statements are generally applicable to all compressors.
Failure to follow any of these precautions may results in severe personal injury,
death, property damage and/or compressor damage
1.3 PRESSURE
A properly sized pressure relief valve must be installed in the discharge piping ahead (upstream)
of any shutoff valve (block valve), heat exchanger, orifice or any potential blockage point.
Failure to install a pressure relief valve could result in the rupturing or explosion of some system
component. Relieve all pressure internally to the compressor prior to servicing. Do not depend
on check valves to hold system pressure. Do not change the pressure setting of the pressure relief
valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with a
plug. Over pressurization of system or compressor components can occur, resulting in death,
severe personal injury or property damage. Do not operate the compressor at pressures in excess
of its rating. Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed
air system. Failure to ensure system compatibility with compressor piping is dangerous.
1.4 FIRE AND EXPLOSION
Clean up any spills of lubricant or combustible liquid immediately. Keep sparks and flame away
from the compressor. Do not permit smoking during servicing, such as checking or adding fluid.
Wipe down spills immediately using industrial cleaner as required. Do not use flammable
material for cleaning purposes. Do not operate the compressor in a hazardous environment unless

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the compressor has been specially designed for that environment. Wear personal protective
equipment including safety goggles and clothing during servicing the compressor. Never use a
flammable or toxic solvent for cleaning the air filter or any parts.
1.5 MOVING PARTS
Keep hands, arms and cloths away from the coupling and fans of the compressor. Do not remove
any guards or cabinet panels or attempt to service any compressor part while the compressor is
operating.
1.6 HOT SURFACES
Do not touch any hot surface and parts during the compressor’s operation. Keep all body parts
away from air/oil receiver tank, steel tubing, airend and after-cooler. Wear personal protective
equipment including gloves while servicing the compressor.
1.7 PROPER COMPRESSED AIR APPLICATIONS
Air from this compressor will cause severe injury or death if used for breathing or food
processing. Air used for those processes must meet OSHA and applicable industry regulations.
This compressor is designed for use in the compression of normal atmospheric air only. No other
gases, vapors or fumes should be exposed to the compressor intake, nor processed through the
compressor. Keep personnel away from the compressed air discharge. Use compressed air for
cleaning purpose, only with effective chip guarding and personal protective equipment which
meet OSHA standard and/or any federal, state, local codes, standard and regulation.
1.8 ELECTRICAL SHOCK
Never start the compressor unless it is safe to do so. Do not attempt to operate the compressor
with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting
and locking out all power at the source or otherwise disabling its prime mover so others who
may not know of the unsafe condition cannot attempt to operate it until the condition is corrected.
Install, use and operate the compressor only in full compliance with all pertinent OSHA
regulations and/or any applicable Federal, State, and Local codes, standards and regulations.
Never assume it is safe to work on the compressor because it is not operating. Many installations
have automatic start/stop controls and the compressor may start at any time.

Page 7KRSL series
NOTICE
- Follow all maintenance procedures and check all safety devices on schedule.
- Use the correct compressor fluid at all time
- Do not rely on the discharge check valve to isolate the compressed air service line
- Keep panels closed at all times and stay away from hot surfaces to prevent hazards
NOTICE
These instructions, precautions and descriptions cover KRSL series air compressors.
As a service to our customers, we often modify or construct packages to the customer’s
specifications. This manual may not be appropriate in those cases.
Every effort has been taken to ensure complete and correct instructions have been included in
this manual. However, possible product updates and changes may have occurred since printing
this manual. Kaishan Compressor reserves the right to change specifications without incurring
any obligation for equipment previously or subsequently sold.

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General Information
2.1 INTRODUCTION
The KRSL series offer models with power ranging from 30 hp to 200 hp (22 kw to 150
kw)These direct driven compressors have standard full load pressure rating from 100 psi to 175
psi (7 bar to 13 bar). The compressor is a single stage, positive displacement, fluid-flooded rotary
screw. A complete package consists of following:
Compressor (Air End)
Electric motor
Starter
Air Inlet System
Compressed Air Discharge System
Lubrication and Cooling System
Capacity Control System
Instrumentation Panel
Air and Fluid Cooling System
Air/ Fluid separation tank (Reservoir)
All components are assembled on a structural steel base with enclosure. The control panel is
located in the front of the enclosure door panel. Acoustical enclosure is one of the standard
features for all compressors.
NOTICE!
Dismantling the compressor’s enclosure may void its warranty.

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2.2 THE COMPRESSION CYCLE
The rotary screw oil-injected vacuum pump is a specific form
of rotary positive displacement pump using a dual screw
airend as the principal element in air compression.
The compressor housing contains of two rotors; Male and
Female rotor. The male rotor has five lobes and female rotor
has six flutes. They are constantly and precisely meshed and
housed in the cylinder with two parallel adjoining bores. All
parts are machined to exacting tolerances. The rotors provide
positive-displacement internal compression smoothly and
without surging. As the rotors rotate, air is drawn into the
cylinder through the inlet port. A volume of air is filled and trapped as the rotor lobes pass the
inlet port in the cylinders. Compression occurs as the male rotor rolls into the female flute,
progressively reducing the space thereby raising the pressure. Compression continues until the
lobe and flute pass the discharge port. The compressed air is then discharged into the air/oil
separator tank. There are five complete compression cycles for each complete rotation of the
male rotor.
When the compressor is operating, a partial vacuum is produced at the compressor inlet. Fluid is
injected into the compressor unit and mixed with the air. The fluid has three basic functions:
•As a coolant, it controls the rise in air temperature normally associated with the heat of
compression.
•It seals the leakage paths between the rotors and stator and between the rotors themselves.
•It acts as a lubricating film between the rotors allowing one rotor to directly drive the
other, which is an idler.
After air/fluid mixture is discharged from compressor to the reservoir, fluid is separated from the
air in the separator tank. Compressed air then flows through the after-cooler for moisture
removal while the lubricant is being cooled by the fluid-cooler for re-injection.
2.3 MOTOR
The main motor is a variable speed induction motor. Operating conditions of the variable speed
motor are as follows (may vary with different countries).
Ambient temperature ≤40℃Altitude ≤1000m

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Main motor transmit power to airend through a flexible, vibration-reducing coupling. There
should be no intermittent or unusual noises or vibrations when the motor is running during
unload or load condition.
The voltage and frequency of power source for the motor is indicated on the nameplate, the
motor can be operated continuously at the rated power × service factor. If the frequency of the
power source deviates from the rating value indicated on the nameplate by 2% of this value, or
under voltage/overvoltage exceeds 10%, there can be no guarantee that the motor will deliver
rated output power.
2.4 COMPRESSOR LUBRICATION AND COOLING SYSTEM
The lubrication and cooling system consists of a reservoir, centrifugal fan, fan motor, aluminum
finned fluid-cooler and after-cooler, thermal valve (or variable speed fan drive) and fluid filter.
High pressure forces the lubricant through a series of direction changes in the reservoir where it
is separated from the air. The fluid is then delivered to the thermal valve and fluid-cooler. Cooled
fluid will be filtered before being re-injected back into the compressor.
The thermal valve is a directional valve with a temperature sensitive device. The thermal valve
fully closes the access to the fluid cooler when the fluid temperature is below 70°C (158°F).
Fluid (below 158°F) will bypass the fluid cooler, flow through fluid filter and re-inject into the
airend. As the fluid temperature rises continually up to 80°C (176°F), due to heat of compression,
the thermal valve begins to operate, and fluid will flow through the fluid cooler.
Ambient air is being forced through the cooler fins by the centrifugal fan, which cools the fluid
and compressed air in the cooler tubes. The after-cooler helps separate the water content in the
discharge air, and through the automatic condensate drain, the water will be drained. This avoids
water contamination problems downstream (in service lines). Cooler fins must be kept clean at
all times.
For the air-cooled units power in the range of 110kw to 250kw, fluid from reservoir circulates to
oil fluid-cooler directly. There is no thermal valve equipped for these motor ranges. A fan drive
controls the fan motor speed up and down to meet discharge target temperature.
2.5 COMPRESSOR DISCHARGE SYSTEM
Air/fluid mixture is forced into reservoir after compression. The reservoir has two basic
functions:
•It acts as a primary fluid separator.

Page 11 KRSL series
•It serves as the compressor fluid sump.
The compressed air/fluid mixture enters the reservoir and is directed against the internal baffle.
Turbulent flow occurs, and velocity is significantly reduced, thus causing large droplets of fluid
to form and fall to the bottom of reservoir. Fluid collected in the reservoir will then be returned
to the compressor due to the pressure differential.
The sight glass enables the operator to visually monitor the reservoir fluid level. Fluid is added to
the reservoir by removing the fluid filling cap after all system pressure is relieved. The fluid
level should remain at the top red line on the sight glass. Fluid refill is required once its level
drops below the lower red line.
The minimum pressure check valve of KRSL units assures the reservoir maintains a minimum
pressure between 7psig and 15psig (0.5Bar and 0.7Bar) during unloading conditions. The
minimum pressure check valve of KRSL units assures the reservoir maintains a minimum
pressure between 15psig and 25psig (1Bar and 1.7Bar) during unloading conditions. This
pressure is necessary for air/fluid separation and fluid circulation.

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2.6 AIREND, INLETVALVE AND FILTRATION SYSTEM
The compressor inlet system consists of an air filter, inlet valve. & SKY airend. The inlet valve
controls the air intake volume. It is also acts as the check valve to prevent the reverse pressure
and rotation when compressor is shutting down.
SKY air end
inlet valve
Casing for air filter

Page 13 KRSL series
Fluid Information
3.1 FLUID GUIDE
KRSL compressors are filled & tested with Kaishan lubricant. Refer Figure 3-1 for filler port,
sight glass, quarter-turn valve location on the reservoir. The compressor is filled with the
manufacturer’s recommended quantity of Kaishan fluid. Inspection of the reservoir fluid level
during installation or operation is recommended.
Figure 3-1: Fluid Fill Location
Do not use different fluid. Using different fluid will void compressor’s warranty.
3.2 FLUID CHANGE RECOMMENDATIONS
Air/Oil Separator Tank
Fluid Fill Port
Sight Glass
Fluid Drain Valve

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LUBRICANT FLUID CHANGE FLUID FILTER
CHANGE
SEPARATOR
CHANGE
KTL8000 Every 8,000 hours
or as indicated by
sampling report
Every 2,000 hours
or as indicated by
Delta P
Every 8,000 hours
or as indicated by
Delta P
KTL4000 FG Every 4,000 hours
or as indicated by
sampling report
Every 2,000 hours
or as indicated by
Delta P
Every 8,000 hours
or as indicated by
Delta P
Installation

Page 15 KRSL series
4.1 COMPRESSOR MOUNTING, SUPPORT AND LOCATION
The compressor should be located on a flat surface in a clean, well-lit and well-ventilated area.
The location must have sufficient access for maintenance equipment and lifting vehicle. Four
feet (4’) of clearance around the compressor is recommended for daily inspection and easy
access to all compressor components. The area must have sufficient lighting for technicians to
safely operate the compressor as well as perform maintenance work. The location should be free
from standing water.
The compressor’s base must be installed on a level surface that can support the gross dead
weight of the machine. Rubber pad with 5 - 15mm thickness or pliable material should be placed
under the bottom of the base if floor surface is uneven or irregular.
NOTICE!
Brand new compressor has “Orange Color” shipping bracket installed under
airend assembly. Please remove the bracket after the unit is installed.
Removal or paint over of safety labels will be a safety hazard. This could result in
personal injury or property damage. Warning signs and labels should be conspicuous
and on a bright legible surface. Do not remove any warning, caution or instructional
material attached with unit.
4.2 VENTILATION AND COOLING
Ambient temperature should not exceed 40°C (104°F). High ambient temperatures may result in
high air temperature shutdown.
NOTICE!
Compressor must be equipped with high-ambient option if operating
temperature exceeds 40°C (104°F).
NOTICE!
Do not install and operate compressor if the ambient temperature is below 5°C
(41°F). Pre-heat option must be instal
led with the unit for lower ambient
temperatures.

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The compressor air inlet must be located in the opposite direction to other compressors or heat
generating equipment. The object is to avoid hot air being drawn into the system. Do not block
the exhaust air from cooler or fan. Hot exhaust air must be vented outside through a duct to
prevent high ambient room temperature. The compressor room must be properly ventilated to
avoid compressor high temperature shutdown.
Maintain clean & fresh air, dust free, metal particle free and chemical vapor free in
the compressor’s room. Housing the compressor within a poorly ventilated enclosure
will cause higher operating temperature.
Under no circumstances should a compressor be installed in an area exposed to
toxic, volatile or corrosive atmosphere, nor should toxic, volatile or corrosive agents
be stored near the compressor.
All models are intended for indoor installation; however, it is possible, with certain
modifications, to accommodate some outdoor locations. Models with standard enclosure are
water-resistant but not water tight. Shelter is needed to protect the unit from rain, snow and
freezing temperatures. An optional weather hood or air grille could be installed to protect
compressor against blowing rain and snow as well as cabinet heater additions if ambient
temperature will be below 2°C (35 F).
4.3 PIPING CONNECTION
Before installation, review the complete air systems layout, which includes vacuum pump(s) and
all related components. Never use PVC pipe or non-genuine rubber hose in the vacuum
distribution system. Use flexible connections to prevent pipe load from being transmitted to the
vacuum pump. It is very important to use adequate pipe diameter for the vacuum network, pipe
size specified by the manufacturer for the vacuum pump unit is recommended.
A service line shut off valve must be installed after the compressor air outlet connection with a
pressure relief valve installed to release compressed air to the atmosphere. For a single
compressor and air receiver tank, manual shut off valves are typically being installed. A union
connector must be installed after the ball valve (quarter turn, shut off valve) at the compressed
air outlet. This will allow unit isolation for maintenance.

Page 17 KRSL series
Release system pressure by opening manual pressure relief valve prior to servicing.
Failure to relieve system pressure could result in death or serious injury and property
damage.
The compressor after-cooler comes with an automatic condensate drain. The drain line should be
installed to remove the condensate during compressor operation.
A receiver tank should be installed if compressed air demands fluctuate. Service line piping is
recommended to be sized to match the compressor’s discharge connector. All piping & fittings
should be rated to withstand greater pressure than the discharge pressure. Isolation valves &
drain valves are installed to isolate the compressor when service is required. These valves should
have water drip legs with the drain direction facing downward to the floor. Piping should all line
up properly with an adequate loop radius or bend radius given for easy installation and to prevent
bending stress, flow restriction and damage due to thermal expansion. Piping support brackets
must be mounted independent of the compressor and motor. This will avoid damage caused by
vibration.
Pressure relief valves are sized to protect the system. Never change the pressure setting or tamper
with the valve. Only the valve manufacturer and their authorized representatives are allowed to
make such changes.
Pressure relief valves are used to protect system integrity in accordance with safety
standards. Failure to provide properly sized valves will result in death or serious
injury.
Pressure relief valves are installed prior to any potential blockage point such as shutoff valves,
heat exchangers and discharge silencers. Ideally, the valve should be threaded directly into the
pressure point it is sensing, not connected with tubing or pipe. Always direct discharge from
relief valves to a safe area away from personnel.
4.4 FLUID LEVEL INSPECTION
Inspect the fluid level when the compressor is in shut down mode to make sure fluid has not
leaked from the unit during transport. Fluid level is indicated on the reservoir sight glass. When
the compressor is running, the level should not exceed the top red mark on the sight glass.

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4.5 ELECTRICAL
Before installation, the electrical supply should be checked for adequate wire size and capacity.
User must comply with national & local electrical codes. The codes specify the surrounding
clearance requirement for the electrical panel. Wiring work should be undertaken only by a
qualified electrician in compliance with OSHA, national or local electrical code. KRSL
compressors provide wiring diagrams for user reference. Refer to the electrical control schematic
in the parts manual for wiring diagrams. A dedicated and fused disconnect switch or circuit
breaker should be purchased for the installation. Any unreasonable voltage imbalance (5%)
between phases must be eliminated and low voltage problems must be corrected to prevent
excessive current draw. Air compressors must be grounded in accordance with applicable codes,
regulations and requirement.
Kaishan Compressor would like to emphasize the importance of providing adequate
grounding for air compressors. The common practice of grounding units to a
building’s structural steel may not provide adequate grounding protection, as paint
and corrosion build-up may exist.
All electrical supply cables must be adequately sized to prevent overheating due to
current draw.
Enclosure panels and drive grille must be fastened in place before starting the
compressor and never removed before lock out / tag out of the main power supply.
A knock out is provided for an incoming power connection. If a different location for the starter
hole is needed, the certified technician must make sure to keep control box clean after the hole is
created. The original hole must be capped if another hole is used. Inspect incoming voltage to
match the compressor’s specification. Inspect motor starter and overload heater sizes. Check all
electrical connections L1-L2-L3 for tightness and cleanliness.
4.6 MOTOR ROTATION INSPECTION
Motor rotation must be checked after the wiring has been installed. Operating the compressor in
incorrect rotation will result in severe damage to the compressor and warranty coverage will be
voided. Motor rotation can be viewed through the opening in the drive grille. The drive motor
end of the compressor is marked with an arrow noting the proper rotation.

Page 19 KRSL series
To inspect rotors rotation, pull out the EMERGENCY STOP button and press once, quickly
press the START and STOP button in sequence, allowing the motor to turn 2 or 3
revolutions. Observe the drive shaft for correct direction. If reverse rotation is observed,
disconnect the power supply, reverse power input leads at the motor starter. Recheck for proper
rotation.
4.7 FAN ROTATION INSPECTION
Fan motor rotation should be inspected. KRSL compressors uses a centrifugal fan for cooling.
Fan rotation is inspected through an arrow shaped observation hole above the fan motor. The fan
must rotate in the direction indicated by the arrow.
NOTICE!
Always inspect fan rotation through the observation hole. Never assume the fan
rotation is correct based on the induced air flow across the coolers. A centrifugal
fan can pull the airflow across the coolers when rotating in either direction;
however, incorrect rotation will cause high discharge temperature.

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Compressor Controller Operation
5.1 BASIC OPERATION
5.1.1. Screen display and basic operation
Power up screen: Boot up screen, after 5 seconds:
Normal display screen:
Icon touch screen display:
Line Pressure
Discharge Temperature
Current
Voltage
Fan Status
Compressor Status
Total Run Hours
Total Load Hours
Run Parameters
User Parameters
Factory Parameters
Calibration Set
Sequence Parameters
Configuration
Parameters
Maintenance Parameters
VSD Settings
Touch Calibration
Schedule Setup
Schedule Activate
Fault History
Motor VSD
Fan VSD
Date and Time Set
Return