501.

170
BS 50/60
 BS50
BS60

KAESER COMPRESSORS, INC 511 Sigma Drive • P.O Box 946 • Fredericksburg, Virginia 22404
Tei. (540) 898-5500 • Fax. (540) 898-5520
 IMPORTANT

Read entire service manual before operating

unit or performing any maintenance.

Always shut off power to unit at main dis­

connect switch before attempting any main­
tenance. All system pressure should be dis­
charged unless manual instructs otherwise.

Use only 'Kaeser Compressors' approved

replacement parts.

Compressed air from any oil lubricated Kaeser

compressor is not suitable for use in any
breathing apparatus or food related process.
(Food grade oils are available on request)

I ATTENTION

Kaeser Compressors declines responsibility

for any modifications made to any Kaeser
compressor other than those made at the
Kaeser factory or those made with prior
written permission from Kaeser Compressors.
 KAESER
COMPRESSORS

Page
1. Dimensions and specifications 2
2. Description of the SIGMA screw compressor 2
3. Design and function of the unit 3/4
4. Installation 5
4.1 Ventilation of the air-cooled units 5
b 2. Air discharge connection 6
4.3 Electrical connection 6
4.4 Overload relay adjustment 7
5. Preparation for initial start-up 7/8
5.1 Malfunction, KAESER CONTROL 9
5.2 Idle time adjustment 10
5.3 Pressure switch adjustment 10
6. Maintenance schedule 11
6.1 Air inlet filter 11
6.2 Filter mat 12
6.3 Oil filter 12
6.4 Oil separator 13
6.4.1 Filter replacement 13
6.4.2 Mounting of the elastic pipe connection 13
6.5 Compressor oil specification 14
6.5.1 Adding oil 14
6.5.2 Oil change
6.5.3 Synthetic oils
6.6 Temperature gauge and high temperature switch 16

6.7 Motor lubrication 16

6.8 V-belt tension 17
6.8.1 V-belt changing 17

6.9 Checking the cooler 18

6.10 Spare parts list 19

6.11 Maintenance check list 20
7. Wiring diagram 21/1 -4
8. Checking the safety valve at the oil-air sump 22
9. Automatic condensate drain 23
BS/CS 3-06.85

10. Dimensional drawing BS 24

11. Dimensional drawing CS 25

12. Transportation instructions 26

13 Conversion instructions for Screw Compressors Model BS/CS 27
from soundproofed to super soundproofed design
 MAESER
COMPRESSORS;

1. DIMENSIONS AND SPECIFICATIONS

Maximum Free air delivery Mntnr

Dimensions
Model pressure unit
inches
psig cfm kW hp length - width - height

BS 44 110 170
BS 44 145 155 30 40
BS 44 190 135
BS 50 110 195
BS 50 145 165 30 40 62 x 40 i/4 x 52 3/4
BS 50 190 145
BS 60 110 240
BS 60 145 205 37 50
BS 60 190 178
OS 75 110 282
CS 75 145 252 45 60
CS 75 190 215
CS 90 110 345
CS 90 145 300 55 75 70 1/2 x 44 i/2 x 56 3/4
CS 90 190 260
CS 120 110 458
CS 120 145 390 75 100
CS 120 190 340

2. DESCRIPTION OF THE SIGMA SCREW COMPRESSOR

The main components of the Sigma Screw Compressor consist of housing and two rotors.
The compressor operates according to the rotary piston principle and is driven by an
electromotor through V-belts.

discharge

Figure 1

There are two rotors with antifriction bearings in the housing: a male rotor with 5 lobes
driven by the motor and a female rotor with 6 voids. While the rotors are turning, air is
drawn in through the inlet port at the upper side of the housing and the trapped air is
compressed at the lower side.
The oil injected into the housing at the lower side absorbs the heat produced by the
compression process, prevents the rotors from coming into contact and lubricates the
antifriction bearings.
As there are no unbalanced forces, inlet or outlet valves, smooth running of the unit
is ensured.
o
 MAESER
COMPRESSORS

3. DESIGN AND FUNCTION OF THE UNIT

Figure 2

7) minimum pressure
thermostatic valve check valve

differential pressure switch

discharge valve
shutoff valve
micro oil filter

vacuum switch control

differential
pressure
switch

in et
va ve

pressure
01 coo er gauge

0) air-cooled connecting oil level

aftercooler temperature indicators
0 gauge
compressed air
outlet 189 pressure
switch

excessive temperature switch

"3) check valve ,5) combined
pressure gauge oil-air sump.
BS/CS 3-09.82
 KAESER
COMPRESSORS

AIR FLOW OIL CIRCULATION SAFETY CHAIN

o Air inlot filter @ Combined oil-oir sump (to) Pressure gauge

Cleans intake air Separates oil from comprossod Indicates the pressure at dischargo
air and directs tho oil back to
Screw compressor circulation (20) Safety vulve
G) Protects the oil-air sump against
The air is compressed. Tho heat 0 Micro oil filtor
produced by compression is ab­ exceeding tho maximum pressure
sorbed by tho oil. Cleans the total oil flow through
a fino replaceable oil cartridge (21) Temperature gauge
(S) Chock waive Indicates the final compression
Prevents the backflow of oil­ (12) Thermostatic valve temperature at the airend
air mixture Controls the oil temperature and
(22) Excessive temperature switch
thus prevents moisture separation
Connecting tubo in tho compressed air and in the Cuts out the compressor at excessive
with elastic pipe connection oil. temperature (212°F measured at the
Result: cold oil is directed back airend)
Combined oil-air. sump to the compressor -
warm oil closes this (23) Oil stop valvo (deenergized closed)
Serves as oil storage sump and for passage and is then directed
first stage of oil/air separation Regulates oil flow into compressor
to the oil cooler
and thus eliminates excessive load
Oil separating cartridge on the motor
(Kl) Oil cooler (air-cooled)
Separates the oil from comprossed Cools the heated oil (24) Oil level indicators
air
Maximum and minimum oil levels
(m) Oil stop valve (deenergized closed) can be checked through two sight
Minimum pressure chock valve
Opens tho passage for oil Injection glasses
Safeguards compressor lubrication after the compressor has been
by maintaining minimum pressure started and closes it when tho (25) Control valvo (deenergized closed)
within oil sump for adequate compressor has been stopped
lubrication at all times Supplies prossure to the control
cylinder of the inlet valve and
(T|) Oil return lino with nozzle discharge valve or ventilates them.
Air-cooled oftorcoolor
Directs the oil, separatod in the The control valve is controlled by
The comprossed air is cooled almost oil separator, back to tho inlot the pressuro switch 18.
to ambient temperature side of the compressor
(2e) Pressure switch
Compressed air outlet
Shuts down the unit if the V-belts
Air pressure can be taken from a are broken, if the direction of
threaded or flanged connection rotation is wrong or if tho unit is
operating on one phaso only

(57) Differential pressure switch

CONTROL
Indicates tho contamination of the
oil separating cartridge

(Tg) Inlot valve (28) Differential pressure switch

Opens at full load and closos when Indicates tho contamination of tho
the compressor is idling or stopped. oil filtor
The inlet valve is controlled by the
control valve. (29) Vacuum switch
Indicates the contamination of the
(77) Discharge vahro intako filter
Ventilates the oil-air 6ump when
the compressor is idling or stopped.
Result: low idling powor,
loadloss starting
This valve is pneumatically controtlod
by the control valve.

(Fa) Pressure switch

Controls the compressor between
full load and idling tjme

4
 HAESE R
COMPRESSORS

4. INSTALLATION

4.1 Ventilation for air-cooled units

Installation of the screw compressor should take place according to the following schedule.
For easy access and service, respect the minimum distances indicated below.

Figure 3
BS

The compressor room should provide adequate ventilation.

Possibility A Possibility B Required size at

Model Ventilation: fan Exhaust air is air inlet entrance
used for heating for A and B
cfm at a static pressure
of 0.4 inches WC wxh inches sq. ft.
— - .. ........................
BS 44 5000 27 x 30 6.5
BS 50 5000 27 x 30 6.5
BS 60 6200 27 x 30 8
CS 75 7700 36 x 34 10
CS 90 9500 36 x 34 13
CS 120 14000 38 x 40 17.5
 KAESER
COMPRESSORS'

Possibility A:

Air delivery of the exhaust fan must be adequate for the size of the unit (see chart on
page 5).

Possibility B:

Warm exhaust air is forced through a duct into the room to be heated. Consult KAESER
COMPRESSORS for maximum allowable pressure drop in exhaust ducts.

To ensure trouble-free operation of the unit, cooling air temperature should not drop
below 40°F and not exceed 100°F.

4.2 Air discharge connection

The unit is piped ready for operation. It must be connected to the air line with a
flexible connecting hose. A check valve is not required in the discharge line as on© is
built into the unit.

4.3 Electrical connection

The unit is wired ready for operation and it needs only be connected to the supply line.
Pull the cable with conductors LI, L2, L3 and earth E through the openings of the base
frame Into the controller and connect them to the terminals marked LI, L2, L3 and
earth E. The main disconnect switch and main fuses must be supplied by the purchaser.
This main disconnect switch must have a minimum switching capacity which is 1.1 times
the indicated rated power of motor.

The required fuses and cross sections of cables are shown in the following chart.

WYE-Delta start WYE-Delta start

230V, 3-phase, 60 cycles 460V, 3-phase, 60 cycles
Model Motor Fuse dual Conductor Fuse dual Conductor
element wire size element wire size
kW hp Amps AWG Amps AWG
•
BS 44 30 40 100 1 60 6
BS 50 30 40 100 1 60 6
BS 60 37 50 150 1/0 80 4

CS 75 45 60 200 3/0 100 3

CS 90 55 75 225 4/0 125 2
CS 120 75 100 300 350 MCM 150 2/0

6
 I I

KAESER
COMPRESSORS

4.4 Overload relay adjustment

WYE-Delta start 460 V, windings WYE-Delta switching.

Only the phase current of a winding is led through the overload relay. This phase current
is only 0.58 time the motor rated current lM, accordingly the relay has to be adjusted
for lN x 0.58.

Adjustment:
The overload relay should be adjusted approx. 10 % higher than phase current of a winding.
This will prevent it from acting at voltage fluctuations.

5. PREPARATION FOR INITIAL START-UP

Every Screw Compressor is operated and thoroughly tested at the factory before shipment
to make sure the compressor delivers its rated capacity and is in good working order.
However, all the care given at the factory will not prevent possible damage during transit.
We recommend the unit be carefully inspected for evidence of possible damage in shipment.
During the first few hours of operation, the machine should be watched for any possible
malfunction.

Comply with the following recommendations before initial start-up

• Do not operate the compressor at a voltage other than the one specified on the
compressor nameplate.

• Do not operate the compressor at pressures exceeding the maximum pressures

indicated on nameplate.

• Install the compressor in an area where the air inlet temperature is at least 40°F
but no higher than 100°F.

• If an air outlet duct is provided, it should be at least the size of the cooler surface
and its length should not exceed 13 ft.

• Install the compressor to maintain a distance of 2 ft. between the cooling air inlet
of the unit and the wall.

• Check for proper direction of rotation.

BS/CS 3 -04.84

• Make sure the shutoff valve (figure 22) is open.

• Shut off the unit, tighten up all the screws in the control box (repeat this after
50 operation hours).

• Make sure the maintenance doors are closed.

7
 KAESER
COMPRESSORS

Start-up after oil change and/or long standstill

The following procedure must be observed when starting the unit after an oil change
and/or a standstill period of three (3) months and over.

To add oil in the airend intake port:

Before starting the unit, pour oil in the airend intake port, in quantites below
recommended and rotate the airend by hand.

Model Quantity
BS 44 1 pint
BS 50/60 1 quart
CS 1 quart

Important:

Use the same brand and quality of oil as the one being used to operate the compressor
unit only (refer to the specs label on the oil separator tank), or drain oil from the
oil separator tank and use for that purpose.

Caution:

Discharge pressure in unit before draining any oil.

To add oil, unscrew the air inlet connection at the inlet port, open the butterfly valve
by hand and pour recommended amount oil into the airend. Screw air inlet connection
back on.

To increase Wye time at start-up:

For start-up, increase Wye-Delta time relay to 30 seconds to prevent compression of

inlet air during start-up. Stop unit by pushing stop button JUST BEFORE REACHING THE
30 SECOND LIMIT.
Once this is done, the Wye-Delta time relay must be set back to its normal operating
point according to the following chart.

Model WYE time

BS 9 sec.
CS 75/90 9 sec.
CS 120 12 sec.

These two preventive measures will ensure that the airend is getting sufficient oil when
starting up the unit and will provide sufficient time for filling the oil cooler and all
oil lines.

7a
 KAESER
COMPRESSORS

Checking the direction of rotation:

- Push momentarily start and then stop button (parts 6 and 7, figure 4) and check for
proper direction of rotation.

- Arrows on motor and airend housing indicate direction of rotation.

- Should direction of rotation be incorrect, conductors LI and L2 must be interchanged.

Important:

If the compressor rotation is wrong, pressure switch No. 26 (figure 2) will automatically
shut compressor off.

Compressor start-up Instrument Panel

- Cut in main disconnect

switch

A
- Push start button
(part 6, figure 4) DC) o p
Compressor stop

- Push stop button

(part 7, figure 4)

- Shut off main disconnect Figure 4

switch
1 Outlet pressure of unit
2 Temperature gauge
3 Hourmeter (service hours)
Important: 4 Hourmeter (full load hours)
5 KAESER CONTROL
Do not shut off the compressor 6 Start button
operating with load at the 7 Stop button
main disconnect switch. 8 Reset button
BS/CS 3 - 09.82

Q
 KAESER
COMPRESSORS

5.1 Malfunction

Safety system: KAESER CONTROL

KAESER CONTROL
(^2) reset button 1 Overload of motor (overload relay)
2 Excessive temperature
3 Airend - low pressure
o 4 Oil filter contamination
o shut down
functions
5 Oil separator contamination
o 6 Air inlet filter contamination
o
o indicating
lights
o

Figure 5

In case of malfunction (lights 1,2 or 3) the compressor is shut down by:

1 Overload relay of the motor.

After having eliminated the trouble, push first the contact pin at the overload relay,
then the reset button (figure 5). Now the compressor is ready for operation.

2 Thermostatic switch for final compression temperature will shut unit off when temper­
ature reaches 212°F.

3 Pressure switch (No. 26, figure 2) at the air outlet port of the airend will shut down
the unit if the direction of rotation is incorrect or the V-belts are broken or have
slipped. This pressure switch is jumped during the WYE-time.

Maintenance requirements are monitored by indicating lights 4, 5 and 6 with warning

functions only.

4 Differential pressure switch (No. 28, figure 2) indicates oil filter contamination.

5 Differential pressure switch (No. 27, figure 2) indicates oil separator contamination.

6 Vacuum switch (No. 29, figure 2) indicates air inlet filter contamination.

Watch and check indicating lights 4 and 5 after unit has been running for a minimum of
5 to 10 minutes from start-up. Warning light 6 will stay on until cartridge is cleaned.

During any one of the above malfunctions, the reset button red light will come on.
To restart unit, press reset and "ON" buttons.
BS/CS 3 - 09.82

To check whether the warning lights are working, press reset button. All lights should
come on.
 KAESER
COMPRESSORS
5J2 Idle time adjustment

The time delay relay for idling time is located in the control box (time 0.5-10 minutes).
The idling phase should be set in such a way that the maximum permissible cutting
in frequency of the motor is not exceeded.
Cutting in ft equency (per h) Cutting in f requency (per h)
Model Model IP 44
IP 23 IP 44 IP 23
BS 44 15 8 CS 75 15 15
BS 50 30 15 CS 90 15 8
BS 60 1 15 15 CS 120 8 8

5.3 Pressure switch adjustment Adjustment of the switch differential at the

pressure switch for limiting the switching
frequency.
Maximum frequency of idling operation:
twice a minute
By increasing the switch differential between
cut-out and cut-in the switching frequency
can be reduced to a limited extent. If this Is
not sufficient a larger air tank is required.
The pressure switch has been pre-set at the
factory as follows:
□>
110 psig units: 100 to 110 psig (A p = 10 psi)
145 psig units: 135 to 145 psig (ip = 10 psi)
190 psig units: 180 to 190 psig (ip = 10 psi)
Pressure adjustment can only be carried out
at the mounted pressure switch when the air
tank is under pressure.

Cut-out pressure:

For higher pressure: turn handwheel to the^kiht

for lower presssure: turn handwheel to the
at 190 psig max. pressure
Cut-in prossure/swltch differential:
2a To increase the difference between cut-in and
vn 71
cut-out pressure:
1V1
VA — remove locking pin
120
7 'i press handwheel so that the cross pin at
7* 1I the top of the handwheel comes out,
XX 1
80 1 then turn handwheel to the left
L J- place in locking pin.
DO W W> 160 ISO 200 220 240
cut-out pressure ■ ■ — psig To decrease the difference between cut-in and
cut-out pressure:
•
remove locking pin
proceed as indicated above but turn hand­
wheel to the right
BS/CS 3-06.85

place in locking pin

Caution
Before removing the pressure switch cover,
shut off the compressor (stop button and main
disconnect switch). After each readjustment at
pressure switch, place cover on pressure switch
before switching on the compressor.
 KAESER
COMPRESSORS

6. MAINTENANCE SCHEDULE

Always follow maintenance instructions:

- Before performing any maintenance on the unit, cut off main disconnect switch to make
sure the power is off.

- Before restarting, make sure no one is working on the unit and covering plates are
back on.

- After switching on main disconnect switch, start unit by pushing start button.

- In case of power failure or cutoff at main disconnect switch, restart unit manually by
pushing the start button.

- The socket to vent the tank is placed in a plastic bag inside the control box. It is used
for maintenance work, such as oil refill, oil and filter change.

6.1 Air inlet filter

Clean the air inlet filter, when the warning light 6 of KAESER CONTROL (figure 5)
comes on.

Shut off the compressor (stop button and main

air inlet filter cartridge
disconnect switch).

Opening of the filter housing (figure 10):

Remove and empty dust container.
Important: Make sure dust container is
reassembled correctly.

Cleaning by tapping off the dust (figure 11):

Tap the front side of the cartridge against
your palm until all the dust has fallen out.
Avoid damaging the cartridge. Clean the
contact surfaces of the gaskets.

Blow clean with compressed air (figure 12):

Blow dry compressed air (no higher than
70 psig) slanted against the paper pleats.
Then blow clean the inside of the cartridge
thoroughly.

Cleaning by rinsing (in case of oily dust):

Add industrial solvent to lukewarm water and
agitate cartridge. Rinse thoroughly in clean
water, shake and dry (figure 13). Never use
gasoline, lye solutions or hot fluids.

Replace cartridge after several cleanings or

if cartridge is overly contaminated.

Figure 13
11
 COMPRESSORS

6.2 Filter mat

Clean filter mat every 100 to 300 operating hours depending on amount of dust.

- Shut off the compressor (stop button and main

disconnect switch).

- Remove cover frame with a screwdriver.

To mount, turn screws 90° (figure 14).

Cleaning:
Rinse the mat in water of approx. 100°F
with some fine washing detergent. Cleaning
can also be done by tapping, vacuuming, or
blowing the dust off with compressed air.
With oily dust, rinse the mat in safety solvent^^
or warm water.

- If mat is excessively soiled, replace.

6.3 Oil filter

Replace the oil filter after the first 100 to 200 hours (depending on environment), there­
after every 2000 to 3000 service hours, or when warning light 4 of KAESER CONTROL
comes on.

- Shut off the compressor (stop button and main

disconnect switch).

- Place vent socket into hose coupling (1 , figure^U)

at the tank (the tank loses its pressure).
Then wait about 1 minute until the oil settles.

- Unscrew clogged filter by turning the filter

counterclockwise and discard.

- Clean sealing surface at the filter head

thoroughly with lint-free cloth.

- Lubricate the filter gasket lightly with oil.

- Screw in the new filter manually until the

cartridge gasket fits tightly. Do not use any
tools! Pour oil into the sump to normal level. #

Important:
BS/CS 3-09.82

Remove vent socket from hose coupling. Start up

the compressor and check for leakage.

Figure 18
 KAESER
COMPRESSORS.

6.4 Oil separator

If the cartridge is contaminated (indicated by warning light 5 of KAESER CONTROL),

replace. Start by pressing start button. The unit is ready for operation.

6.4.1 Filter replacement - Shut off the compressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Place vent socket into hose coupling at the
tank (the tank loses its pressure), see 6.5.1.
- Loosen self-locking nuts 5 and 6 of the elastic
pipe connection and remove bracket halves.
- Loosen pipe fittings (1), remove screws (3)
and sump head (4).
- When changing the oil separating cartridge,
unscrew and replace screen filter (7). This
filter is mounted on the oil return line at
the sump head.
- Replace the two gaskets (D). All the afore­
mentioned components come with the spare
oil separating cartridge.
- Assemble parts in reverse order.
- To install elastic pipe connection, please
refer to 6.4.2.
- Remove the vent socket.

6.4.2 Mounting of the elastic pipe connection

- Cutting edge "a" of pipe 1 has to be

burr-free and surface "b" clean.
- Place cone ring holder 3 and cone ring 2
on pipe 1.
- Place pipe 1 into sleeve 7 without preliminary
stress; push cone ring 2 with cone ring holder 3
up to the cone end of sleeve 7 (realign the
pipe, if necessary).
- Place the bracket halves 4 on the cone ring
holder and sleeve and tighten according to
measurement "s".
Measurement "s" is a recommended value
Figure 20 and can fluctuate by approx. 2 %.
- Tighten locking screws so as to allow adjusting
Model d Order No. by hand when the unit is off. When the unit
BS/CS 3 - 09.82

s
is operating at full load, all screws must be
BS 44 Ws (1.38) 2 21/32 (2.66) 5.1390.0 under equal load.
as 1 za>32 (1.9) 3 W32 (3 22) 5.1391.0 After the self-locking nuts 5 and 6 have been
tightened and loosened several times they have
cs 21/1 (2.38) 3 23/32 (3.72) 5.1392.0
to be replaced.
Dimensions in inches
 KAESER
COMPRESSORS

6.5 Compressor oil specifications

The oil used for cooling the screw compressor
ENERGOL THB 46 during operation must have the following properties: '
<3? ENERGOL HLP 46
-
-
high aging resistance
high dispersive power
- low emulsifiability
HYSP1N AWS 46 - minimum capacity for forming foam

Basic oil: solvent raffinate

Oievron OC TURBINE OIL 46
Hydraulic or turbine oil: viscosity class VG 46
CALTEX REGAL OIL Viscosity at 104°F: approx. 42-50 cSt
R+O (200-230 SU sec)
Flash point, surface

g£ONI NUTO H 46
temperature:
Pour point:
above 392°F
at least 18°F below low
ambient temperature

To ensure trouble-free operation, use only one

Mobil D.T.E OIL MEDIUM of the oil types listed on the left. These oil
types are of comparable quality and can be
purchased from the listed oil companies or
ROTELLA 10 W* service stations.
X 100 Motoroil 10 W The order in which the oils are listed is not
Shell
indicative of or related to the quality of. the

BSI
oils.
RANDO OIL HD 46
The oil companies reserve the right to change the
names of the oil designations!
02.25.85
‘The oil sort "Rotella X 10 W" is mixable with
the filled in oil sort "Shell comptella oil 46"
respectively "Shell oil S. 9159"

6.5.1 Adding of oil

Check oil level daily at the oil sight glass.
Always shut compressor off when checking.. .
the oil. Oil must be added when the minimum
oil level, which is the middle of the lower
oil sight glass, has been reached. Fill to the
middle of the upper oil sight glass, no higher.
DO NOT OVERFILL.
- Shut off the compressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Place vent socket (1) into coupling (2) at the •
tank (the tank loses its pressure).
- Loosen locking screw (5) at the filling vent.
- Pour oil in to the max. level.
- Check gasket and tighten locking screw (5).
BS/CS 3-02.85

- Remove vent socket (1) from coupling.

Important:
Always use the same make and type of oil.
(indicated on the oil-air sump)
Figure 21
14
 KAESER:
COMPRESSORS

6.5.2. Oil change

The oil must be changed approx, every 2000 to 3000 service hours depending on contam­
ination of inlet air.
If the unit operates at or close to ambient temperature of 100°F (for example in boiler
rooms etc.) the oil must be changed more frequently, i.e. every 1000 - 1500 hours.

Important: Drain all oil from the oil/air sump, cooler and lines.

Oil change with pressure produced by another

source:
- Shut off the compressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Close shutoff valve.
- Hook hose (3, figure 21) of other pressure
source to socket (1, figure 21) onto tank
and pressure feed.
- Remove hose with socket (the tank should
have a pressure of approx. 30 psig).
- Slowly open tank drain valve (4, figure 21).
The pressure remaining in the tank Will
cause the oil to flow.
- After discharging air tank, slowly open the
cooler drain plug (the oil will drain without
pressure).
- Close drain valve and drain plug.
- Open shutoff valve.
- Oil adding see item 6.5 and 6.5.1.

Oil change with pressure produced by the

compressor:
- Shut off the compressor (stop button and main
disconnect switch).
- Open maintenance doors.
- Close shutoff valve.
- Let compressor run for about half a minute.
- Shut compressor off (stop button and main
disconnect switch).
Important: - Slowly open tank drain valve (4, figure 21). a
For restart procedure please refer The pressure remaining in the tank will
to instructions on page 7a. cause the oil to flow.
- After discharging air tank, slowly open the
cooler drain plug (the oil will drain without
BS/CS 3-10.84

Model Oil charge

pressure).

BS approx. 9 i/< US Gal - Close drain valve and drain plug.

CS 75/90 approx. 16 US Gal - Open shutoff valve at the tank cover.

CS 120 approx. 18 1/2 US Gal - Oil adding see item 6.5 and 6.5.1 .
15
 I !/l 4-dl":
COMPRESSORS

6.5.3 Synthetic Oils

The following synthetic oil brands have been approved for use in KAESER screw
compressors:

Manufacturer Brand Name

Nuodex Anderol 497

Keystone KSL 220

Also any other brand with the same specifications. Consult KAESER COMPRESSORS for
brands not listed.

Two important requirements are:

Viscosity at 175° F: 10-12 cSt

Foaming Test ASTM D 892-74: Sequenz II 20/0

Extra care must be taken when changing from mineral oil uso to synthetic oil or
when changing oil brands. Make sure that all oil In the separator tank, oil lines,
oil cooler and airend has been drained.

When switching from mineral oil to a synthetic oil it is recommended that the
first change of synthetic oil be replaced after 100 h of operation, along with
the oil filter. This is because the synthetic oil will act as a solvent and remove
deposits left by the mineral oil. Once the compressor is free of deposits, follow the
recommended oil and filter change interval.

Also, when switching from mineral oil to a synthetic oil, the plant system materials
must be re-evaluated. Certain plastics are not compatible with synthetic oils.
The following is a partial list of acceptable and not recommended materials:

Acceptable Not Recommended

Viton Neoprene
High Nitrile Buna N SBR Rubber
Teflon Low Nitrile Buna N
Epoxy Paint Acrylic Paint
Oil-resistant Alkyd Lacquer
Nylon Polystyrene
Delrin PVC
Celcon ABS

Consult KAESER COMPRESSORS, INC. for details or materials not listed.

Caution: synthetic oils are not compatible with polycarbonate bowls. Any such
bowls in the compressed air system should be covered with metal bowl guards or
replaced with metal bowls.
BS/CS 3-03.85

15a
 KA I M:1
COMF’RESSORS

6.6 Temperature gauge and high temperature switch

When final compression temperature reaches 230° F, the compressor shuts off and warning
light 2 (excessive temperature) on the KAESER CONTROL (Figure 5) comes on.
Troubleshoot and repair.
Probable causes: malfunction in the cooling system, e.g.:
low oil level
extreme ambient temperature (too low or too high)
clogged oil filter
clogged oil cooler
clogged filter mat
To restart, press reset (8) and start (6) buttons (Figure 4).
The compressor is back in operation.

6.7 Motor lubrication

Models BS 44 up to CS 90:
The standard motors have life-time grease lubrication.
Under normal working conditions (ambient temperaure 40° F), carry out maintenance
of the motor bearings according to the following chart.
After the indicated working hours, demount motor bearings, rinse them and fill
the void spaces with new grease.

Model CS 120:
The standard motors are equipped with relubrication system.
Under normal working conditions (ambient temperature 40° F), carry out relubrication
of the motor bearings according to the following chart.
After the indicated working hours, relubracte motor bearings with the indicated
amount of grease.

Lubrication interval Amount of grease

Model
operating hours ounce

BS 44 16 000 -
BS 50 32 000 -
BS 60 32 000 -
CS 75 32 000 -
CS 90 32 000 -
CS 120 8 000 3/4

We recommend the following brands of lithium base grease: BP Energrease LS 3

Calypsol H 443
Exxon Beacon 3
BS/CS 3-09.85

Mobilux Grease 3
Shell Alvania 3
SKF Waelzerol FL

Under harder working conditions, l.e. strongly polluted intake air and ambient temperature
of the unit, approx. 105° F, lubrication interval is half as long.

For special motors, other protective systems etc., follow manufacturer's instructions
(on motor name plate).
16
 COMPRESSORS:

6.8 V-belt tension

Belt tension must be checked every 500

operating hours.

The V-belt span is adjusted automatically

within a limited range by the pressure spring.
See figure at left.

An indicator pin 3 in the oblong hole indicates

the V-belt span. When the pin 3 reaches the
top of the hole, retensioning is required.

- Shut off the compressor (stop button and

main disconnect switch).
- Loosen hex nut 1.
- Retension the V-belt by turning the hex
nut 2 until the pin 3 is all the way down.
- Retighten hex nut 1.

6.8.1 V-belt changing

- Shut off the compressor (stop button and
main disconnect switch).
- Open left maintenance door.
- Unscrew and remove covering plate
from fan frame.
- Place V-belt first over the free­
standing fan blade, then turn fan and
move belt over the other blades.
- Turn adjusting hex nut (2, Figure 23)
at the swing support downwards.
- Slip V-belt over motor and compressor
pulleys.
- Tension V-belt. (see section 6.8.)
- Fasten covering plate on the frame.
- Close maintenance door.
- Check V-belt tension after approx. 2
BS/CS 3-06.85

and 24 operating hours.

Important:
Figure 24 Spare V-belts must be marked SPZ and be
100 % oil resistant.

17
 KAESER
COMPRESSORS

6.9 Checking the oil cooler and air aftercooler

Contamination of the cooler can be checked

through an inspection hole. Its location is
indicated on figure 25.

Check cooler at least every 1000 operating

hours.

Clean cooler

- Remove covering plates A and open the

left and the upper maintenance doors.
- Unscrew air pipes B and C, valve combination D
and control line E from the cooler.
- Loosen screws F and swivel the cooler out­
wards.
- If cooler is contaminated, blow clean cooling
fins with compressed air from inside or spray
with water.
- Reassemble parts in reverse order.
BS/CS 3 - 09.82

18
 KAESER
COMPRESSORS

6.10 Spare parts list

Maintenance parts

Maximum V -belt Oil filter Oil separation Air inlet Filter

pressure cartridge cartridge filter mat
Model compl.set compl. set cartridge

psig pcs. Order No. Order No. Order No. Order No. Order No.

110 4 6.2540.0
BS 44 145 4 6.2540.0 6.1981.0 62012.0 6.1996.0 6.1 938.0
190 4 6.2540.0
110 6 6.1434.0
BS 50 145 6 6.2533.0 6.1981 .0 6.2012.0 6.1996.0 6.1938.0
190 6 6.2542.0
110 6 6.2532.0
BS 60 145 6 6.1 434.0 6.1981 .0 6.2012.0 6.1996.0 6.1938.0
190 6 6.2533.0
110 9 6.1 432.0
CS 75 145 9 6.2521 .0 6.1 981.0 6.2013.0 6.1 997.0 6.1945.0
190 9 6.2522.0
110 9 6.2529.0
OS 90 145 9 6.1432.0 6.1981.0 62013.0 6.1 997.0 6.1945.0
190 9 6.2521 .0
110 9 6.2529.0
CS 120 145 9 6.1432.0 6.1981.0 62013.0 6.1997.0 6.1945.0
190 9 6.1432.0

Hoses

Hose line Hose line

Model Vent line Oil stop valve
Order No. Order No.

BS 8.0864.0 8.1139.0
CS 75/90 8.0806.0 8.1138.0
CS 120 8.0806.0 8.1100.0

When ordering spare parts always state compressor type, serial number and year of
manufacture which are stamped on the nameplate.

Important:

Order KAESER genuine factory-tested replacement parts only !!

io
 MAESER
COMPRESSORS,

6.11 Maintenance check list

Record hours of operation and check maintenance work performed.

Record values where indicated.

replaced Oili'f ,er

Filter Air Oil

cartridge
mat filter sepa­ Oil fill V-belts
car­ rating
Hours of tridge car­ Date Signature
operation tridge

retensioned
_ ..

■o
--------------

replaced
replaced

replaced
replaced

checked

checked
a>
cleaned
cleaned

refilled
«
a.
<x>
—
BS/CS 3-09.82

20
 I

KA E SER
COMPRESSORS

7. Wiring diagram for BS.CS, St 501.170 Page 1

21/1
 KAESER
COMPRESSORS,

7. Wiring diagram for BS.CS, St 501.170 Page 2

A B

13
1

12 I U I s'. I S5 I s6 I I A2/0
6

10

11

12

13 11,12,19

14 12,14,18

15

16 15

17 14.20

10

19

20

21 22. 25

22 3,20,21

23 21,22

24 16,24

25

21/2
 KAESER
COMPRESSORS
7. Wiring diagram for BS,CS, St 501.170 Page 3

21/3
 I’M 4-4 4:1
COMPRESSORS

7. Wiring diagram for BS,CS, St 501.170 Pays 4

IM Motor starter (main contactor) Malfunction Indicators:

2M Motor starter (delta contactor) 10L Overtoad relay for motor
shutdown
3M Motor starter (wye contactor) ETS Excessive temperature switch
functions
20L Overload relay for transformer SAPS Safety air pressure switch
T Transformer HOFP High oil filter pressure
indicating
M Motor HOSP High oil separator pressure
lights
APS Air pressure switch HAFP High air filter pressure
CR1/2/3 Control relay
ISV Solenoid valve (controls inlet valve/
discharge valve)
3SV Solenoid valve (oil stop)
TRI Time delay relay (delay-off)
TR2 Time delay relay (wye time)
1PB Push button "off'
2PB Push button * an *
0 Indicating light (green, ready for operation)
1R Indicating light (red, off)
HM Hour meter
LUM Load hour meter

2 0L CR1 CR2 CR3 TRTR

1 2

WIRE DUCT

|230[ 0 |23Q|oT

IM

10L

Terminals

460V 3Ph 60Cy

21/4
 KAESER
COMPRESSORS

8. CHECKING THE SAFETY VALVE AT THE OIL-AIR SEPARATOR

To check the set maximum operating limit and the blow-off capacity, the unit must be
operated at a final pressure higher than maximum setting of the pressure switch.

Maximum pressure Set maximum operating

of the unit pressure of the safety valve

110 psig 130 psig

145 psig 175 psig

190 psig 210 psig

• except Model CS 120: 175 psig

In order to avoid readjustment of the pressure switch, carry out checking in the
following way:

Shut off the compressor (stop button and main disconnect switch).
Close the shut off cock at the discharge line (Figure 22).
Close the shut off cock downstream of the unit.
Start the compressor and let it switch over to idling.
While the discharge line is being closed the pressure can easily be checked as
it is increased slowly up to the limit where the safety valve will react.
Shut off the compressor and proceed in the reverse order.
BS/CS 3-06.85

O'
 KAESER
COMPRESSORS.-

9. AUTOMATIC CONDENSATE DRAIN (OPTIONAL)

The condensate collected in the air tank is drained automatically by a solenoid valve
at regular intervals.

The solenoid valve is controlled by a time delay relay with timers at which the opening
times of the solenoid valve can be preset from 0.4 to 10 seconds and the intervals from
1.5 to 30 minutes, depending on the amount of condensate.

Install a dirt trap in front of the solenoid valve to catch larger dirt particles and thereby
ensuring the solenoid valve's proper operation. Clean the strainer of the dirt trap at regular
intervals.

Make sure the dirt trap and solenoid valve are properly installed in the direction of the
arrow. .

Connect a hose to the solenoid valve for the condensate to reach the sump.

23
 KAESER
COMPRESSORS

10. DIMENSIONAL DRAWING BS-air cooled with soundproofing casing

Dimensions in inches

connection
BS/CS 3-05.84
 kaeser
COMPRESSORS'

11. DIMENSIONAL DRAWING CS- air cooled with soundproofing casing

Dimensions in inches

I I Dimensions specially
for CS 120

O o

£
CM

electrical connection
BS/CS 3-05.84
 SI

KAESER
COMPRESSORS

12. TRANSPORTATION INSTRUCTIONS

Model Weight
BS 44 approx. 1520 lbs.
BS 50 approx. 1850 lbs.
BS 60 approx. 1940 lbs.
CS 75 approx. 2490 lbs.
CS 90 approx. 2600 lbs.
CS 120 approx. 2930 lbs.

Dimensions in inches

lift truck
8S/CS 3-09.82
 COMPRESSORS;

13. Conversion instructions for Screw Compressors Model BS/CS

from soundproofed to super soundproofed design

(2)

Demount the steel plate with filter Screw the quick-changeable frame
frame at the right end off the steel plate

Screw the quick-changeable frame Fasten the screws in the threads of

on silencing box the supporting frame (at both ends
of the unit)

<5>

Screw the extra plate (delivered with

the other parts) on frame and now
fasten the two boxes on both ends
of the unit with hexagon nuts
27
 BS 50
BS 50

% - PARTS MANUAL
*X
- RECOMMENDED
SPARE PARTS LIST

A 20
B2O
-----,—
C 20
D2O

I
 INDEX

Pano No.

SECTION 1 Introduction 3

Foreword

Description

To order parts

Recommended spare parts

Caution

SECTION 2 Parts list 4-15

SECTION 3 Recommended spare parts 16-19

SECTION 1 INTRODUCTION

1. FOREWORD •

This manual is provided for the operator's use and reference when ordering parts.
An illustrated parts breakdown is included for parts identification. All compressor
parts meet the manufacturer’s highest quality standards used in the manufacture
of the original equipment.

2. DESCRIPTION

The parts breakdown lists every part, assembly and sub-assembly of the compressor
unit. Each part is identified with a number. The location of and relationship between
parts are clearly illustrated. Questions pertaining to the number, description and
quantities needed for each assembly are dealt with in the following pages.

3. TO ORDER PARTS

When ordering parts, furnish the following information to prevent any error:

- Mode! designation and serial number of the unit as shown on compressor

nameplate.
- Reference number, part number, description and quantity required as listed.

4. RECOMMENDED SPARE PARTS LIST

A recommended spare parts list is provided at the end of this manual. The list
indicates the description, part number, the quantity used in the compressor, and
minimum quantities which should be carried to ensure maximum protection of
the compressor. The recommended spare parts inventory to be kept on hand varies
according to the location of the nearest distributor, and is broken down as follows:

A. Local distributor
B. Nearby distributor
C. Remote distributor.

5. CAUTION

NEVER use parts other than the ones approved by the manufacturer and listed in
this parts manual. The use of parts not approved by the manufacturer may result
in hazardous conditions, over which the manufacturer has no control, bodily injury,
and damage to the compressor unit. Such action would invalidate the manufacturer's
warranty of the compressor unit.
SECTION 2 PARTS LIST

Title Page
No.

Frame, Casing 5

Driving system 6,7

Oil tubes, Vent lines 8

Control tubes, Compressed air tubes 9.10

Vent valve n

Inlet valve 12

Check valve 13

Minimum pressure check valve

Combination valve 15

4
 Frame, Casing BS 50> BS 60 type

Ref. Qty Part Bio Descr iption Ref. Qty . Part No Description
1 1 4.9320.0 Frame
1) 2 I 7.2305.0 Controller 31 4 6.0653.0 Spring washer
2) 2 1 7.2306.0 Controller 32 2 6.0660.0 Toothed lock washer
3 1 _4.9257.0. Casing complete with 3a 33 2 6.0681.0 Hex. nut M 5
3o 1 6.1939.0 Quick-change frame 34 2 6.0682.0 Hex. nut M 6
4 1 4.7019.1 Cosing 35 4 6.0684.0 Hex. nut M 8
5 1 4.8324.0 Cosing
1 4.8325.0 Casing
% 6
7 1 4.7071.1 Door
8 1 4.7072.1 Door
9 1 4.8323.0 Door
' 10 1 4.7070.1 Cover sheet 1) Compressor Unit BS 50
n 1 4.8305.0 Cover p lote 2) Compressor Unit BS 60
12 1 4.7349.0 FiIter mat
13 1 4.7347.0 Filter mat
14 1 6.1938.0 Filter mat
15 1 4.7348.0 Covering grating
16 1 4.7346.0 Covering grating
17 4 6.1347.0 Anti-vibro’ion pods dia.3T>/T)x 315/®’
18 2 5.1331.0 Gas spring
19 1 5.1398.0 Gasket profile 185 *
20 1 5.1403.0 Froth rubber band 13 *
21 4 Split pin •
5.1330.0
22 1 6.2344.0 Slud M 10 x 35
23 49 6.0916.0 Philips head screw M 5 x 10
24 2 6.0901.0 Philips heed screw M5x 15
25 3 6.0986.0 Sheet metal screw 3,5x95
26 4 6.0726.0 Hex. hd. screw M 3 x 20
27 4 6.2203.0 Hex, hd. screw M 16 x 20
28 2 6.0622.0 Washer
29 12 6.0623.0 Washer
30 4 6.0627.0 Washer
 Driving system BS 50. BS 60 type

Ref. Qty Part No Description Ref. Qty Part No Description

1 1 1.3851.3 Screw compresso. Sigma 2 21 1 4.7207.1 Intermediate ring

1-3) 2 1 7.0960.0 Motor 3-phase 30 kW, 23O/46OV 22 1 4.7225.0 Intermediate ring
4-6) 2 I 7.0961.0 Motor 3-phose 37 kW, 230/460 V 23 1 4.8321.0 Distance washer
'-3) 3 1 4.7283.1 Motor pulley dio. 12 19/32' 24 9 6.0725.0 Hex. hd. screw M 8 x 15
4-6) 3 I 4.7 2 84.) Motor pulley dio. 12 19/32" 25 1 6.0730.0 Hox. hd. screw M 8 x 40
1) 4 1 4.9876,0 Compressor pulley dia.g 3/|6* 26 2 6.0763.0 Hex. hd. screw M 10 x 30
2) 4 1 4.9877.0 Compressor pulley dia.9 39/64' 27 1 6.0772.0 Hex. hd. screw M 10 x 55
J) 4 1 4.98 78.0 Compressor pulley dio.)) 17/64' 28 1 6.0798.0 Hex. hd. screw M 10 x 70
I) 4 1 4.9S79.0 Compressor pul ley dia.6 11/16" 29 2 6.2215.0 Hex. hd. screw M 12 x 25
5) 4 1 4.9880.0 Compressor pulley dia.7 43/64' 1 -3) 30 4 6.0799.0 Hex. hd. screw M 12 x 75
5) 4 1 4.9881.0 Compressor pulley dia.8 13/16" 4-6) 30 4 6.0819.0 Hex. hd. screw M 16 x 60
') 5 1 6.1636 0 Set of v-belts 31 4 6.2210.0 Hex. hd. scrow M 14 x 40
2) 5 1 6.2533.0 Set of v-bclls 32 4 6.2200.0 Hex. hd. screw M 14 x 60
J) 5 1 6,2542.0 Set of v-bclls 33 5 6.0813.0 Hex. hd. screw M 16 x 40
’) 5 1 6.2532.0 Set of v-bcits 1-3) 34 1 6.0795.0 Hex. lid. screw M 20 x 100
5) 5 1 6.1434.0 Set of v-belts 1-6) 34 1 6.0777.0 Hex. hd. screw M 20 x 65
S) 5 1 6.2533.0 Set of v-belts 35 3 6.0617.0 Split pin
6 1 5.0684.0 Fan wheel 36 10 6.0623.0 Wosher
7 1 5.1074.3 Cooler 37 2 6.0631.0 Washer
8 1 4.8328.0 Fan case 38 2 6.0624.0 Washer
9 1 Sk 1426.73 Cover plate 1-3) 39 4 6.0625.0 Washer
10 1 4.6327.1 Swing frame 1-6) 3? 4 6.0627.0 Washer
II 1 4.7566.1 Balance adjustment 1-3) 40 4 6.0633.0 Washer
12 1 4.6326.0 Whip 1-6) 40 4 6.2376.0 Washer
13 1 4.7572.1 Shaft 41 2 6.0633.0 Washer
14 1 4.6322.0 Pivot bcoring 42 8 6.0626.0 Washer
15 4 6,1329.0 Base of the machine 43 8 6.0627.0 Wosher
-3) 16 4 4.7593.0 Steel plate 44 2 6.0629.0 Washer
17 2 4.7428.0 Hinge 45 10 6.0653.0 Sprinq washer
18 1 4.7588.1 Centering disk 46 2 6.0654.0 Spring wosher
19 1 4.7592.0 Disk -3) 47 4 6.0655.0 Spring wosher
20 1 5.0428.0 Disk 1-6) 47 4 6.0657.0 Spring washor
Driving system BS 50. BS 60 type

Ref. Qty Part No Description

48 4 6.0656.0 Spring washer

49 4 6.0657.0 Spring woshcr
50 2 6.0684.0 Hex. nut M 8
51 4 6.0685.0 Hex.nut M 10
1-3) 52 4 6.0686.0 Hex. nut M 1 2
4-6) 52 4 6.0688.0 Hex. nut M 16
53 8 6.0687.0 Hex. nut M 14
54 4 6.0688.0 Hex. nut M 16
55 2 6.0693.0 Hex. nut M 20

1) Compressor Unit BS 50; 110 psig

2) Compressor Unit BS 50; 145 psig
3) Compressor Unit BS 50, 190 psig
4) Compressor Unit BS 60; 110 psig
5) Compressor Unit BS 60; 145 psig
6) Compressor Unit BS 60; 190 psig
 Oil tubes , Vent lines BS 50, BS 60 type

Ref. Qty Ptirt No Description Ref. Qty Part No Description

1 1 4.8870.1 Combi nation valve 31 2 5.0567.1 Gasket for inlet valve

2 1 6.1981.0 Filter cartridge 32 1 6.1524.0 Gosket R 1/2.”
3 1 7.1366.0 Oil slop volve R 3/4" 33 4 6.2411.0 Cylinder screw with inside hex
4 1 4.7387.1 Inlet valve 11 M6x 100
5 1 4.7345.0 Vent volve R 1/2" 34 4 6.2342.0 Stud M 10 x 65
6 I 6.1917.0 Air filter complete 35 2 6.0631.0 Wo,her
6a 1 6.1996.0 Filter cartridge 36 2 6.0684.0 Hex. nut M 8
•j 6b 1 6.1920.0 Support for air filler 37 4 6.0685.0 Hex. nut M 10
J 7 1 4.7324.2 Flange 38 I 6.1527.0 Gasket R 3/4*
8 1 7.0294.0 Vacuum switch (-19 11/16 “ wg)
9 1 7.0298.0 Protecting cap
10 1 B.0259.0 Ball cock R 1/2"
11 1 4.1850.0 Copper lube
12 1 4.8307.0 Tube
13 I 8.0864.0 Hose line R l/2"xl9 11/16 "
14 1 8.1139.0 Hose lino R 3/4"x28 47/64 "
15 1 Hose line R l/8"xl 49/64 "
16 1 9.1078.0 Hose R3'x25 25/64 "
17 2 9.0659.0 1 lose clip
18 1 6.1969.0 Si lencer
19 1 6.IH3.0 Angle R 3/4"
20 1 6.1062.0 Elbow R 1/2"
21 2 5.0784.0 Ooublc nipple R 1/2“
22 1 5.0785.0 Double nipple R 3/4”
23 1 6.1030.1 Fitting R 1/2"
24 1 6.1033.0 Fitting R 3/4?
25 1 5.0925.0 Reducing socket R 3/4" x R 1/2"
26 1 6.0274.0 Pipe fi lling R 3/4"
27 1 6.0251 .0 Angle fitting R 1/8"
28 1 6.0259.0 Angle filling R 3/4"
29 2 5.1423.0 O - ring dia. 3/4xl/8 "
30 1 5.0532.0 Rubber-sleeve
 Control tubes , BS 50. BS 60 type
Compressed air tubes

Ref. Qty Part No Description Ref. Qty Part No Description

1 1 3.5056.4 Tank I3gal. /203psig *26 2 4.8435.0 Steel plote

2 1 4.7238.1 Cover 27 3 5.H25.0 Tension clamp complete
3 1- 6.1960.0 Oil separator cartridge 28 3 5.1391.0 Gasket ring
4 1 4.7342.0 Minimum pressure check valve R 11/2 29 3 5.1122.0 Support for gasket ring
30 3 4.3268.0 Sleeve
5 1 4.7393.1 Check valve complete 31 1 4.8309.1 Air tube
6 1 7.0217.0 Difference pressure switch 32 1 4.8308.0 Air tube
7 1 7.1369.0 Solenoid valve 33 1 4.8317.0 Suction tube
') 8 1 7.0220.0 Pressure switch 1l6psig 34 1 4.8297.0 Copper tube R 1/8"
2) 8 1 7.0221.0- Pressure switch 232 psig 35 1 4.8330.0 Copper tubeR 1/8"
3) 8 1 7.0221.0 Pressure switch 232 psig 36 1 4.8329.0 Copper tube R 1/8"
9 1 7.0219.0 Pressure switch 37 1 4.8332.0 Copper tube R 1/8"
10 1 8.0018.0 Pressure gouge 0-360/220 psig 38 1 Control lubeR l/4"x13*
1 8.0137.0 Pressure gauge 0 - 145/110 psig 39 1 Control tubeR 1/4Mx 16 59/64
1) I'
2) II 1 8.0136.0 Pressure gauge 0 - 232/145 psig 40 I Control tvbeR l/4"xl/ 23/32
1 8.0138.0 Pressure gauge 0 - 23^190 psig 4) 1 Control tubcK l/4"x51 11/64
3) I'
1). 12 I 8.0332.0 Safety valve R 3/4", 130 psig .42 1 8.1130.0 Hoso line R 1/4"x27 9/16
2) 12 1 8.0334.0 Safety valve R 3/4", 175 psig 43 1 8.0581.0 Hose line R 1/2“x 59*
3) 12 1 8.0336.0 Sofcty valve R 1/2", 210 psig 44 1 6.1098.0 Angle R 1 1/2"
13 1 8.0197.0 Distance thermometer 45 1 5.0929.0 Protection sleeve R 3/8"
14 2 7.0784.0 Hour meter 46 1 5.0780.0 Double nipple R 1/4"
15 1 7.0449.0 Malfunction refcty 47 1 5.0795.0 Double nipple R 1/4“ x M 12 k 1,5
16 1 7.1083.0 Luminous button green 48 2 5.0820.0 Reducing socket R 1/4" x R 1/8“
17 1 7.1084.0 Luminous button red 49 1 5.0846.0 Reducing socket R 1/2" x R 1/8"
18 1 8.0259.0 Boll cock R 1/2" 50 1 5.0963.0 Reducing socket R 1/2" x R 1/4"
19 I 8.038).0 Dirt trap R 1/4" 3) 51 1 5.0925.0 Reducing socket R 3/4" x R 1/2“
20 2 6.0105.0 Oil sight glass R 3/4" 52 1 6.0390.0 Pipe fitting R 1/4"
21 1 6.0501.0 Locking screw R3/8' 53 1 6.0231.0 Pipe fitting R 1/8"
22 1 9.0817.0 Hose coupling R 1/4" 54 5 6.0246.0 Pipe fitting R 1/8“
23 1 9.0814.0 Hose coupling R 3/3" 55 I 4.8199.0 Pipe fitting R 1/4"
24 1 6.0519.0 Locking scrow R 1 1/4" 56 1 4.8335.0 Pipe fitting P. 1/4"
25 1 4.7454.0 Instrument panel 57 1 6.0229.0 PipO fitting R 1/4"
Control tubes, BS 50, BS 60 type
Compressed air tubes

Ret Qty Part No Description

58 3 6.0266.0 Angle Fitting R 1/8"

59 1 6.0254.0 Angle fitting R 1/4"
60 2 6.0344.0 T pipe fitting R 1/8"
61 2 7.0673.0 Plug PG 16
62 1 5.1443.0 O-ring dia. 25/32x3/32'
63 1 5.1455.0 O-ring die. 1 27/32x5/64'
64 I 5.1422.0 O-ring dia. 2 13/64x1/8'
65 1 5.1462.0 O-ring dia. 3 5/32x5/64*
66 2 6.0470.0 Gasket for pressure gauge R 1/4"
67 2 6.0432.0 Gasket R 1/4"
68 3 6.1521.0 Gasket R 3/8"
69 2 6.0438.0 Gosket R 1/2"
3) 70 1 6.1524.0 Gasket R 1/2"
71 1 6.1527.0 Gosket R 3/4"
72 2 5.0556.0 Gosket for tonk
73 6 6.0914.0 Philips head screw M4x 10
74 2 6.0360.0 Fi IK,ter head screw M 4 x 8
75 2 6.0746.0 Hex. hd. screw M 6 x 10
76 2 6.2214.0 Hex. hd. screw M 8 x 50
77 4 6.0733.0 Hox. hd. screw M 8 x 60
78 4 6.0780.0 Hex. hd. screw M 10 x 110
79 2 6.0821.0 Hex. hd. screw M 10 x 40
80 8 6.0759.0 Hex. hd. screw M 16 x 45
81 6 6.2374 .0 Washer
82 2 6.2373.0 Washer
83 6 6.2431.0 Hex. nut M 8

1) Compressor Unit 110 psig

2) Compressor Unit 145 psig
3) Compressor Unit 190 psig

r
 Vent valve BS 50, BS 60 type
4.7345.0

Ref. Qty Part Na Description

1 1 5.0989.0 Crankcase
2 1 5.0297.0 Cover
3 1 4.9026.0 Piston complete
*3o 1 5.0998.0 Piston »
■ .3b 1 5.1473.0 O-ring dia. 5/8x3/32"
4 t 5.0999.0 Diaphragm
5 4 6.2408.0 Cylinder screw with inside hex.
14 6 1 6.24 8 2.0
M5x12
Stud bolt M5x 8

•
 Inlet valve BS 50. BS 60 type
4.7387.1 /

Ref. Oty Part No. Discription

1 1 4.8930.2 Valve body

2 1 4.8963.0 Shaft
3 1 4.8932.0 Disk
4 1 4.8964.0 Lever
5 1 4.8961.1 Support
6 1 4.8965.0 Hex. nut .
7 1 7.0486.0 Working cylinder
$ 8 1 7.0489.0 Angle joint
9 2 6.0033.0 Boll bearing
10 2 6.0541.0 Guard ring
u 1 4.7564.0 Revet with button hood
>2 1 6.0609.0 Clomping iloeve
13 2 6.0720.0 Hex. hd. screw M6x 15
14 1 6.0723.0 Hex. hd. screw l-A 6 x 45
15 1 6.0701.0 Cap nut M 6
16 3 6.0622.0 Woshcr
 Check valve BS 50, BS 60 type
4.7393.1
&-C&D
>

Ref. Qty Port No. □•Script ion.

1 1 4.8910.2 Volve body

2 1 5.0617.1 Compression spring
3 1 4.9011.0 Valve disk complete
3a J 4.8916.0 Guide bolt
3b 1 4.6915.2 Disk
3c I 4.8914.) Disk
3d 1 5.0565.1 Gasket
1U&

3e 1 6.0700.0 Crown nut M 10

3f 1 6.0649.0 Split pin dio. 2 x 20

r'
i
■
Minimum pressure BS 50, BS 60 type
check valve
4.7342.0

Ref. Qty Part No. Discription

1 I 4.8575.0 Volve body R 1 1/2"

2 1 4.8576.0 Cylinder
3 1 4.9021.0 Piston complete
3o 1 4.8578.0 Piston
3b I 5.1434.0 O - ring 1 27/64'xl/8‘
3c 1 5.1411.0 O - ring 1 1/32x5/32'
4 1 4.9015.0 Valve dirk complete
4o 1 4.8568.0 Bolt
4b 1 4.8577.0 Disk
4c 1 5.1434.0 O - ring 1 27/64'xl/8'
5 1 6.2371.0 Disk
6 1 5.1470.0 O - ring 1 49/64x1/8"
7 1 5.0643.0 Compression spring
8 I 5.0645.0 Compression spring
9 1 6.0686.0 Hex. nut M 12
10 1 6.0945.0 S^J3te-beod bolt M 12 x 40
Combination valve BS 50, BS 60 type
4.8870.1

47

Ret Qty Part No.. Oiscription

1 1 4.8872.1 Valve body

2 1 4.8875.0 Cover
3 1 4.8873.0 Cover
4 1 7.0399.0 Actuoting piston with working element
5 1 4.8874.1 Thread nipple
6 1 5.0636.0 Compression spring
7 2 5.1445.0 O-ring dia. 1 3/8^5/64'
8 1 7.1407.0 Difference pressure switch
9 3 6.2406.0 Cylinder screw with inside hex.
M 5x 16
10 3 6.2400.0 Cylinder screw with inside hex.
M 5 x 20
11 1 6.1534.0 Gosket dia. 25/32'x dio. IS/l^l/l^
 SECTION 3 RECOMMENDED spare parts list

, Model BS 50 / 60

Qty. Recommended
DESCRIPTION Part LOCATION/USE
per Quantities
No.
unit A B C

Lubricating oil filter element 6.1981.0 1 at valve combination 1 2 3

Oil separating cartridge
6.2012.0 1 in oil separator 1 1 2
complete set
Intake air filter cartridge 6.1996.0 1 at air inlet port 2 3 4
Filter mat 6.1938.0 1 at cooling air inlet port 2 3 4
V-belt set for BS 50/110 psig 6.1434.0 1 at motor/compressor pulley 1 1 2
£•^.£33,0145 psig 1 II 1 1 2
190 psig 6.2542.0 1 II 1 1 2
V-belt set for BS 60/110 psig 6.2532.0 1 at motor/compressor pulley 1 1 2
145 psig 6.1434.0 1 11 1 1 2
190 psig 6.2533.0 1 H 1 1 2
Valve plate complete 4.9011.0 1 in check valve 1 1 2
Valve plate complete 4.9015.0 1 in minimum pressure check valve 1 1 2
Inlet valve complete 4.7387.1 1 suction side of airend 0 1 1
Compression spring 5.0617.1 1 in check valve 0 1 1
Compression spring
1/64" x 5/16" x 1 13/32" 5.0643.0 1 in minimum pressure check valve 0 1 1
Compression spring
5/32" x 63/64" x 7 9/32" 5.0645.0 1. in minimum pressure check valve ■0 1 1
O-ring inside dia. 3/4"x1/8" 5.1423.0 2 at valve combination 1 1 2
O-ring ins.dia. 1 27/32"x5/64" 5.1455.0 1 at oil filler neck 1 1 2
Flat gasket 5.0567.1 2- at inlet valve 1 1 2
1 O-ring ins.dia. 25/32"x3/32" 5.1443.0 1 in dirt trap 1 1 2
O-ring ins.dia. 3 5/32"x5/64" 5.1462.0 1 between airend and check valve 1 1 2
O-ring ins.dia. 2 13/64"x1/8" 5.1422.0 1 between check valve and fitting 1 1 2
Gasket ring ins.dia. 1 57/64" 5.1391 .0 3 pipe gasket: 2 separator/cooler o
1 1 c.
1 airend/separator
O-ring ins.dia. 1 3/8"x5/64" 5.1445.0 2 in valve combination 1 1 2
O-ring ins.dia. 1 1/32"x5/32" 5.1411 .0 1 in minimum pressure check valve 1 1 2
O-ring ins.dia. 1 49/64"x1/8" 5.1470.0 1 in minimum pressure check valve 1 1 2
Diaphragm 5.0999.0 1 in vent valve 1 1 2
Diaphragm 7.0347.0 1 in oilstop valve 1 1 2*
Mains pressure switch for
7.0220.0 1 control line from air cooler 0 1 1
110 psig units
Mains pressure switch for
145/190 psig units 7.0221.0 1 control line from air cooler 0 1 1

Safety pressure switch 7.0219.0 1 control line from airend outlet 0 1 1

Valve combination 4.8870.0 1 at oil cooler- 0 1 2
 RECOMMENDED SPARE PARTS LIST

Model BS 50 / 60

Qty. Recommended
DESCRIPTION Part LOCATION / USE
per Quantities
No. c
unit A B

Oil stop valve R 3/4" at valve combination 0 1 2

SK2881 .73 1
compl. pasted
Discharge valve R 1/2" at pipe oil separator /
SK2602.73 1 0 1 1
compl. pasted minimum pressure check valve
Silencer 6.1969.0 1 in 90° elbow before inlet valve 0 0 1
Dirt trap R 1/4" 8.0381,0 1 in oil return line from oil
0 1 1
separator to airend
Hose line R1/4"x27 9/16" 8.1130.0 1 control line to safety pressure
0 1
switch •
Hose line R1/2"x19 11/16" 8.0864.0 1 discharge valve to silencer 0 1
Hose line R3/4"x28 47/64" 8.1139.0 1 oilstop valve to airend 0 1 1
Control valve R 1/8" at pipe oil separator /
SK2866.73 1 0 1 1
compl. pasted minimum pressure check valve
Piston compl. with O-rings 4.9021.0 1 in minimum pressure check valve 1 1 2

1 •

•
 RECOMMENDED SPARE PARTS LIST

FOR ELECTRICAL EQUIPMENT

Model BS 50

WYE-Delta-start

WRE DUCT

Qty. Inpu t vol tage Recomme ided

DESCRIPTION per Part No. LOCATION/USE Qua ntit Les
unit 208 V 230 V 460 V A B C
7.2063.0 X X
1M Motor starter (Main contactor) 1 Control box 0 1 1
7.2067.0 X
7.2063.0 X X
2M Motor starter (Delta contactor) 1 X Control box 0 1 1
7.2067.0
7.2062.0 X X’
3M Motor starter (WYE contactor) 1 Control box 0 1 1
7.2060.0 X
0 :
2 OL Overload relay for transformer 1 7.2201.0 X X X Control box 1 1

7.2224.0 X
T Transformer 1 Control box 0 1 1
7.2221.0 X X

CR 1,2,3 Control relay 3 7.2066.0 X X X Control box 0 1 1

TR 1 Time delay relay (delay off) 1 7.0467.0 X X X Control box 0 1 1

TR 2 Time delay relay (WYE time) 1 7.0466.0 X X X Control box .1 1 2

7.2252 .0 X X
1 OL Overload relay for motor 1 Control box 0 :1 1
7.2250.0 X
 RECOMMENDED SPARE PARTS LIST

FOR ELECTRICAL EQUIPMENT

Model BS 60

WYE-Delta-start
iSU’.

WRE DUCT

IM

10L |

&
Qty. Input voltage Recommended
DESCRIPTION per Part No. LOCATION/USE Quantities
unit 200 V 230 V 460 V A B C
7.2063.0 X X
1M Motor starter (Main contactor) 1 Control box 0 1 1
7.'2062.0 X
7.2063.0 X X
2M Motor starter (Delta contactor) 1 Control box 0 1 1
7.2062.0 X
7.2062.0 X X-
3M Motor starter (WYE contactor) 1 X Control box 0 1 1
7.2067.0
2 OL Overload relay for transformer 1 7.2201.0 X X X Control box 0 1 1
7.2224.0 X •
T Transformer 1
X 0 1 1
7.2221.0 X X
CR 1,2,3 Control relay 3 7.2066.0 X X X Control box 0 1 I
TR 1 Time delay relay (delay off) 1 7.0467.0 X X X Control box 0 1 I
TR 2 Timo delay relay (WYE time) 1 7.0466.0 X X X Control box 1 1 2
7.2253.0 X X
1 OL Overload relay for motor 1 Control box 0 1
X 1
7.2251.0

i
19