Manual R2D2
R2D2
Instruction manual
Betriebsanleitung
Instructions techniques
Instruction manual R2D2
-2-
Index
1.
Introduction
...3
2.
EU-Declaration of Conformity
...4
3.
Description of the machine
...5
4.
Safety
...7
5.
Operation
...8
5.1
Variations of the dust collection
...8
5.1.1 Operation with the container version
...9
5.1.2 Operation with the bag version
...9
Maintenance
...10
6.1
Belt drive
...10
6.2
Compressor
...10
6.3
Water separator
...10
6.4
Filter cartridges
...10
6.
7.
Technical data
...11
8.
Appendix
...11
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
1.
-3-
Introduction
CONTEC would like to thank you for deciding to purchase the R2D2 dust collector.
The R2D2 has been specially developed for connection to floor preparation machinery such as
mobile blast machines, concrete planers and floor grinders to enable a dust free operation.
Even huge quantities of dust can be handled by the R2D2. This means the R2D2 is suitable
for use with high performance machinery. In the CONTEC product range, the R2D2 is
specially used for the MODUL 350 mobile shotblaster and the ORBITER 800 floor grinder.
The R2D2 can be adapted for a wide range of applications not only limited to the construction
industry.
In the following pages, you will find all the necessary information, to achieve a safe, reliable
and highly competent performance from the R2D2. It is therefore important to follow the
strict guidelines for the deployment and servicing of the R2D2 in order to obtain optimum
performance.
It is in the interest of all persons operating or using the machine, to take note of the operating
instructions in this manual in order to be fully conversant with the components and functions
of the R2D2 dust collector.
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
-4-
CONTEC GmbH
Hauptstrasse 146
57518 Alsdorf
2
EU-Declaration of Conformity
According to the Machine Directive 98/37/EC (89/392/EWG), Appendix II A
We hereby declare that the machine
Type:
Name:
Dust Collector
R2D2
conforms with the following standards which have been valid at the date written below:
EC-Directive 98/37/EC (89/392/EEC), in its current wording
EC-Directive 89/336/EEC, in its current wording
EC-Directive 73/23/EWG (89/392/EEC), in its current wording
List of the essential harmonised standards:
EN 12100
EN 418
EN 953
EN 60204 Part 1
EN 1050
„Safety of machines
„Emergency-Stop-Devices“
„Separating safety devices“
„Electric equipment of machinery, general requirements“
„Guiding principles for the risk judgement“
Alsdorf, 10.04.2004
______________________________
(Place and date)
(Authorized signature)
J. Greb – Construction department
_________________________
(Name and function of the authorized person)
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
3.
-5-
Description
Bild 1
Bild 2
R2D2 Power unit
R2D2 Filter unit container version
Bild 4
Bild 3
Compressor
R2D2 Filter unit bag version
Bild 5
Bild 6
Water separator
Dust ports:
Left 70 mm - Right 125 mm
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
Bild 7
-6-
Bild 8
Dust bin bag version
Bild 9
Dust bin container version
Bild 10
Dust bin lifting device
Bild 11
Phase inverter
Bild 12
Plug and socket
Belt drive
Bild 14
Bild 13
Electric and air pressure ports
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
Clamp for dust bin
© CONTEC 2006
Instruction manual R2D2
4.
-7-
Safety
Attention !
The R2D2 dust collector is constructed according to existing safety rules
and regulations. These technical precautions should not be removed or
changed under any circumstances. While operating the machine the
following points should also be kept in mind:
1. Disconnect the machine before commencing any servicing or maintenance work however menial. Never unplug the machine while it is still running. This notice can be
found in every manual but in nearly every part of the R2D2 high electrical currents are
transmitted. The danger of injury is therefore not only from electric shock, but also from
moving parts of the machine.
2. Never wear loose or badly fitting clothing. Flapping sleeves may be pulled into the
machine causing serious injury.
3. All rotating parts of the machine are suitably protected by covers, which prevent clothes
or similar from entering the machine. Under no circumstances should these covers be
removed before the machine is switched on.
4. The R2D2 should be switched off immediately if any unusual noises or vibrations are
detected whilst the machinery is in operation. A thorough check must be carried out in
order to detect the cause.
5. Before leaving the R2D2 the operator must switch off the machine and make sure that it
cannot accidentally roll from it's position. Also disconnect the machine from the mains.
6. Check the power cables regularly as damage may have occurred while operating the
machine. Always disconnect the cables before examination and treat all electrical parts
with extreme care.
7. Always re-connect all the safety plates and covers after any maintenance work.
8. If the noise of the R2D2 exceeds 90 dB(A) ear protections have to be worn by the
operator.
9. The compressor on the power unit is heating up during operation. Don’t touch any part of
the compressor. Danger of burning yourself !
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
5.
-8-
Operation
Important: Before attempting to operate the R2D2 ensure that you are fully familiar
with all the controls and the safety regulations of this manual !
Connect the R2D2 dust collector via the dust hose to the application, for example shotblaster,
floor grinder or floor planer. Make sure that the dust hose is in good condition and without
any tears or other defects. Little holes can dramatically reduce the performance of the dust
collector.
Check the electric cables.
Connect the extension lead to the mains and to the socket on the power unit (picture 11). You
need a 32 A, 400 V, 3 phase power supply. If no other machine will be connected to the plug
of the power unit, a 16 A supply is sufficient.
It is possible to make one unit out of the power and filter unit. On one side of the filter unit
are two clamps in rectangular pipes. Pull them out and turn them 90°. Slide the end of the
clamps inside two holes on the side of the power unit. Now the two units are one machine
which can be moved as one on site.
Connect the 150 mm (diameter) hose from the power unit to the filter unit. Connect the air
pressure hose and the electric connection of the power unit to the filter unit.
Press the „START“ button on the control panel. If the indicator light on it’s right side doesn’t
stay on when you release your finger, then the motor wants to start in the wrong direction. In
this case disconnect the plug (picture 10) on the power unit. The plug is a reverse plug which
means that two phases can be swopped by inserting a screw driver in between the pins and
twisting them round to the opposite direction. This allows the motor to run in the correct
direction. When there is no pressure in the air tank, the compressor starts to work.
Turn the star-delta switch in the „star“ position. The motor begins to turn. Wait approximately
10 seconds before you turn the switch into the „delta” position. It is important to wait long
enough before you switch over from the “star” to the “delta” position. Wait until the
motor is not increasing the speed any more before you switch over. You can now start to
work.
The dust bin of the R2D2 has to be emptied during operation. How often depends on the
amount of dust produced during the application.
Only dry dust or dry material can be removed by the R2D2. Wet or greasy dust blocks or in
the worst case destroys the filter cartridges.
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
5.1
-9-
Variations of the dust collection
Basically there are two methods of collecting the dust with the R2D2. The first one simply
fills the dust container (picture 8) with dust which can then be emptied. The second method
fills a bag within a bin (picture 7). When the bag is full it can be sealed with a string and then
disposed of into a container. Method one reduces waste in the form of plastic bags, method
two reduces the possibility of problematic dust escaping into the air.
5.1.1.
Operation with the container version
Switch the R2D2 "On" (see " 5 Operation"). The dust container (picture 8) is located
underneath the filter cartridges. During operation the dust container will fill up. For emptying
the container switch the R2D2 "Off". There are for clamps (picture 14) which keep the
container underneath the filter unit. Open the clamps and the container will be lowered down
to the floor. There are two handles on the container which allows you to use the container as a
wheel barrow. Empty the container. Fix the now empty container using the steps shown above
in reverse order.
5.1.2.
Operation with the bag version
Remove the bins from the R2D2 dust collector. Place the bag in the dust bin as you would
with a normal dust bin. The opening of the bag must be pulled around the opening of the bin.
Lift the bin with the handle. Connect the vacuum hose. The dust bag will be sucked to the
inner side of the dust bin. This opens the bag and it can be filled with the dust.
Attention !
The vacuum hose must be connected correctly when operating with a dust
bag. If not properly connected the bag will be sucked into the machine.
Open the dust valves. The bag will now be filled during operation. When the bag is full
remove the vacuum hose. The bag will now close around the dust like a "bottle neck". Close
the dust valves. Lower the bins to the floor by raising the lift handles. If necessary the "bottle
neck" of the bag can be sealed with string. This minimises the possibility of dust escaping into
the air. Pull the bins out of the machine and remove the dust bags. Take new bags and start
from the beginning.
Attention !
When the dust bin is removed from the R2D2 and no dust should escape
from the machine, the dust valve must be closed (lever horizontal) and the
ventilator left running. The dust valve is not 100% airtight but because the
ventilator runs continuously, air is also sucked continuously inside the dust
collector. This prevents dust escaping out of the valve.
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
6.
Maintenance
6.1.
Belt drive
- 10 -
The belt drive (picture 12) has to be tensioned periodically. Loosen the four screws which fix
the motor to two rails. Only loosen the screws, don't remove them. Picture 12 shows a screw
in between the ventilator and the motor below the belts. Loosen the nut and turn the screw
clockwise until the belt has the correct tension. The belt shouldn't move more than one
centimetre half way in between the pulleys. Before tightening the motor foot screws check if
the two pulleys of the motor and ventilator are still in line. If they are not in line change the
position of the motor on the rails until the right position is found.
6.2.
Compressor
The oil level of the compressor has to be checked and the water inside the tank has to be
emptied regularly. All necessary information is given in the compressor manual in the
appendix.
6.3.
Water separator
Picture 5 shows the water separator of the R2D2. The water separator separates the water
from the compressed air and makes sure that no water will be pressed inside the filter
cartridges. The separator has to be checked on a regular basis and the tank has to be emptied
when full. The speed with which the tank fills with water depends on the moisture of your
location. To empty the tank open the valve on the bottom side of the separator.
6.4.
Filter cartridges
If the performance of the R2D2 is not sufficient any more or if the filtration is no longer dust
free the filter cartridges have to be checked.
Before you start, the dust collector should be switched on for a while without sucking dust.
The pulse jet cleaning mechanism then removes most of the dust on and around the cartridges.
Remove the dust bin (picture 7 to 9). If you have a bag version, the conical part of the
machine frame (picture 3) has to be unscrewed.
By loosening the wing screws underneath the cartridges they can be pulled out of the
machine. Use air pressure to clean the filters and check them for any damage. If necessary one
or all the cartridges have to be replaced.
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
Instruction manual R2D2
7.
Technical data
7.1
Power unit
- 11 -
Height in cm
148
Length in cm
101
Width in cm
51
Weight in kg
160
Electrical connection
400 V, 50 Hz, 3 Phases, 32 A
Max. airflow in m3/min
38
Max. vacuum
10150 Pa (101.5 mbar)
Filter cleaning system
Pulse jet
Noise level Lwa *
83 dB(A)
Noise level Leq *
71 dB(A)
* Data: VÜA Verein zur Überwachung technischer Anlagen e.V.
7.2
Filter unit container version
Height in cm
Length in cm
Width in cm
Weight in kg
Filter area in m3
Number of filter cartridges
Dust ports in mm
Volume of dust bin in l
7.3
Filter unit bag version
Height in cm
Length in cm
Width in cm
Weight in kg
Filter area in m3
Number of filter cartridges
Dust ports in mm
Volume of dust bin in l
Technical data subject to change
8.
120
105
79
120
10
5
70 / 125
90 standard / 160 optional
165
105
79
120
10
5
70 / 125
2 x 75
Appendix
Diagrams
Wire diagram
Part list
Manual Compressor
CONTEC GmbH Hauptstrasse 146, 57518 Alsdorf, Deutschland/ Germany/ Allemagne
info@contecgmbh.com, www.contecgmbh.com
© CONTEC 2006
R2D2 Stückliste / Parts List
Artikel-Nr. / Part-No.
13-10-01-00
80-21-31-00
80-21-31-60
13-10-01-17
13-10-01-21
13-10-01-20
13-10-01-18
13-10-01-19
50-20-15-56-K
90-26-01-40
1.3645.30310
1.3645.30340
1.3785.20120
90-26-01-43
7.4851.00020
7.4851.00030
90-26-00-63
91-20-01-08
90-26-00-61
90-26-00-60
70-24-10-87
70-24-11-62
90-24-20-12-38
90-24-01-32-US
90-24-01-60
50-20-10-55
50-20-32-02
50-20-32-01
50-26-03-08
50-20-20-13
50-20-20-121
90-26-50-92
70-25-02-25
90-26-52-10
Description 1
Machine Frame R2D2 Power Unit
Wheel R2D2 P
Castor R2D2/Tornado
Left Side Cover R2D2 P
Right Side Cover R2D2 P
Top Cover R2D2 P
Back Side Cover R2D2 P
Front Side Cover R2D2 P
Control Panel complete R2D2
Pressure Tank 40 Ltr. Kompressor R2D2 P
Compressormotor with Pump R2D2 ECO 4
Compressormotor with Pump R2D2 ECO 4
Compressormotor with Pump R2D2 ECO 3
Water Trap R2D2/Tornado
Compressor Pressure Switch R2D2 ECO 3
Compressor Pressure Switch ECO 4/5 D
Silencer R2D2 P
Pipe on the Pressure Side R2D2
Throttle R2D2
Ventilator R2D2
Belt R2D2 US Version
Belt R2D2 P
Taperlock R2D2 P
Motor Pulley R2D2 US Version
Pulley Motor R2D2/Tornado
Motor for Ventilator 5,5 KVA 400 V R2D2
Socket 32 A, 400 Volt, 5P, R2D2 P
Reverse Plug R2D2 P
Cable For Valves R2D2 P
Harting Plug housing at the Powerstetion
Jack in the Housing at the Cable of the
Coupling presure Pipe R2D2
Pressure Hose R2D2 P
Presure Pipe Hose coupling R2D2/Tornado
Description 2
US Version
Low Version
low Version and ECO 2 Tornado
complete R2D2/R2D2-7
cable R2D2/R2D2-7
Powerstation R2D2/R2D2-7
1/2"
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R2D2 Stückliste / Parts List
90-26-52-11
13-10-03-01
13-10-03-10
13-10-03-09
90-26-03-06
50-20-15-14
70-25-11-50-3
90-26-51-16
50-20-20-12
50-20-20-131
90-20-40-40
13-10-05-05
90-20-45-40
90-20-45-41
13-10-05-01
13-10-05-03
80-20-32-60
13-10-04-00
80-20-31-60
13-10-08-00
70-27-01-25
70-27-00-70
13-10-08-01
13-10-06-00
13-10-06-07
90-26-03-08
50-20-15-56
50-20-40-01
50-20-30-PF
51-20-30-01
50-20-30-05
50-20-30-04
50-20-30-02
50-20-30-03
50-20-33-08
50-20-33-07
Presure Pipe Hose coupling R2D2 3/8"
Filter Unit Frame only R2D2
Pressure Pipe for Valves R2D2
Top Cover R2D2 Filter Unit
Cleaning Valve R2D2/Tornado
Electric Panel for Valve Filter Unit
Dusthose 150 mm with Plasticspiral
Plug presure Pipe R2D2 1/2" Treat
Harting Socket housing at the Filter
Harting Plug Pin Mounting at the Filter
Cartridge Filter R2D2/Tornado
Handle For Dustbin R2D2
Spanner Dust Bin R2D2/R2D2-7
Bracket for Spanner Dust Bin R2D2/R2D2-7
Axis For Wheel Dustbin R2D2
Wheel For Dustbin R2D2
Chassis for Wheels Filter Unit R2D2
Rear Wheel Filter Unit R2D2/R2D2-7
Connecting piece between Filter-/PowerPlastic Plug Dustport 125 mm R2D2 F
Filler Cap Dustconection 70 mm R2D2
Connecting piece between Filter-/PowerDustbin 160 Ltr. R2D2
Hights Distance For 160 Ltr. Dustbin
Control Curcuit Valves ET Version R2D2
Control Panel Box only R2D2
Transformer R2D2
Phase Guard R2D2/Tornado
Motor Protective R2D2 5,5 KW, 400 Volt
Auxilary Contact Module Main Contactor
Main Contactor R2D2/R2D2-7
Circuit Breaker C6 R2D2/R2D2-7
Circuit Breaker Control C2 R2D2/R2D2-7
Contact Element M22-K01 R2D2/R2D2-7
Contact Element K10 R2D2/R2D2-7 new
R2D2/R2D2-7
3 Meter R2D2
unit R2D2/R2D2-7
unit R2D2/R2D2-7
unit R2D2 90 Liter Dustbin
unit R2D2 160 Liter Dustbin
R2D2
before July 2004
R2D2/R2D2-7
new Version Mai 2003
Version Mai 2003
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101
107
111
115
117
119
121
123
125
126
127
131
133
135
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141
143
149
151
R2D2 Stückliste / Parts List
50-20-33-061
50-20-23-09
50-20-23-01
50-20-23-02-N
50-20-20-04
1.1814.00100
1.5732.70190
1.5737.40220
13-10-04-04
13-10-05-00
13-10-05-02
4.0228.0
4.0496.1
4.0513.0
4.0580.0
4.1479.00010
4.2186.0
4.2648.00010
4.2792.0
5.0019.1
5.0050.1
5.0209.0
5.0551.1
5.0966.0
5.1309.0
5.1456.0
5.1482.0
5.1482.0
5.5056.0
5.5057.0
50-20-20-06
6.0173.1
6.0199.0
6.0256.00010
6.0356.0
6.0376.0
LED Element for bulb R2D2/R2D2-7 new
Mounting Adapter for Switches R2D2/
Emergency Switch R2D2/R2D2-7 new
Start Button with Light R2D2/R2D2-7
Star-Delta-Switch R2D2
Compressor complete R2D2 ECO 4
Compressor complete for low size R2D2
Compressor complete R2D2 400 Volt 50 HZ
Axis For Wheel Filter Unit R2D2
Dustbin 90 Ltr. R2D2
Bracket for Spanner Dustbin R2D2
Connecting rod for Piston ECO 3/2 R2D2
Filler Plug for ECO 3/2 Compressor
Valve Plate for Compressor ECO 2/3 R2D2
Crank Flange for Kompressor ECO 3/2 R2D2
Angle Fitting 3/8" between Copper pipe
Air Tube Copper ECO 3 R2D2
Airfilter Cover for Compressor ECO3 R2D2
Air Tube ECO 4 R2D2
Pisten for Compressor ECO 4 R2D2
Pisten for Compressor ECO 3 R2D2
Valve Plate for Compressor ECO 4 R2D2
R2D2 Cylinder food Sealing ECO 3 and
Fitting Bolt for Kompressor ECO 3/2 in
Sealing Zylinderfood ECO 4 R2D2
O-Ring big for Zylinderhead ECO 3/2
O-Ring small for Zylinderhead ECO 3/2
O-Ring small for Zylinderhead ECO 3/2
O-Ring big for Zylinderhead ECO 4 R2D2
O-Ring small for Zylinderhead ECO 4 R2D2
Label Mount (Start) 111 R2D2/R2D2-7
Compressor Airfilter ECO 4/5 complete
Airfilter Foam for Compressor ECO3/ECO2
Angle Fitting 3/8" at the cylinder head
Stuffung cone for Angle Fitting ECO 3
Cap Screw for Stuffing Cone ECO 3 R2D2
Version 2003
R2D2-7 new Version Mai 2003
Version Mai 2003
new Version Mai 2003
US Version
ECO 3 400 Volt, 50 HZ
and Tornado
R2D2 and Tornado
and Tornado
and Tornado
and Pressure Hose ECO 3 R2D2
d=70 mm
d=50 mm
ECO 2 Tornado
Crank Flange R2D2 and Tornado
R2D2 and Tornado
R2D2 and Tornado
R2D2 and Tornado
R2D2/R2D2-7
R2D2 / Tornado
ECO 3 R2D2 and ECO 2 Tornado
R2D2
Seite 3 von 4
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161
R2D2 Stückliste / Parts List
70-25-02-50
70-25-11-25
70-25-11-25-K
70-25-11-27
70-25-11-50
70-25-11-50-K
70-26-30-00
70-27-50-30
8.0006.0
8.1366.0
90-24-16-10-38
90-26-00-01
90-26-01-41
90-26-01-42
90-26-03-07
90-26-51-17
90-26-52-12
Underpressure Pipe to Dust Container
Dusthose DN 125 mm
Dusthose DN 125 mm with Plasticspiral
Dusthose DN 127 mm High Temp R2D2
Dusthose 150 mm Diameter 3 Meter R2D2
Dusthose 150 mm with Plasticspiral R2D2
Vibration blocks Compressor Tornado/R2D2
Plastic Plug for Frame Filter Unit R2D2
Pressure gauge 0-16, G1/4" ECO 4/5
Hose line DN 10 x 500 ECO 3 R2D2
Taperlock Motor Delta I / R2D2 US
Pulley Ventilator R2D2/Tornado
Pressure Regulator R2D2 P
Pressure Pipe Compressor to the Tank
Membrane for Valve R2D2/Tornado
Plug presure Pipe R2D2 NW 13
Presure Pipe Hose Double Sided 1/2" R2D2
R2D2 Bag Version
R2D2
Compressor R2D2/R2D2-7
R2D2 ECO 3
Seite 4 von 4
SERVICE MANUAL
E
Reciprocating Compressor
Model: ECO 4 D stationary
GL---Nr.: 1_5737_40220---01 01
Part No.: 1.5737.40220
Serial No.: ...............................................
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg : PO Box 2143 : GERMANY : Tel. + 49---(0)9561---6400 : Fax + 49---(0)9561---640130
http://www.kaeser.com
(&2 '
Table of Contents
Chapter --- Page
1
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
2
Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
-----------
5
6
7
7
7
Correct Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accompanying Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
3
-----------
8
8
8
8
8
Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport with a Fork Lift Truck or Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
4
-----------
9
9
10
10
10
Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11
5.1
5.2
5.3
5.4
6
1
1
1
1
2
2
2
2
3
3
3
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.1
4.2
4.3
4.4
4.5
5
-----------------------
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.1
3.2
3.3
3.4
3.5
4
1
1
1
1
1
1
1
1
1
1
1
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.1
2.2
2.3
2.4
2.5
3
Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Main Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Receiver Charging Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Control (Stop ---Start Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components of the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
---------
11
11
11
12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 13
6.1
6.2
6.3
6.4
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Antivibration Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
---------
13
14
14
15
i
Table of Contents
Chapter --- Page
7
Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 16
7.1
7.2
7.3
7.4
7.4.1
7.5
8
7
7
7
7
7
7
-------------
16
16
17
18
19
19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 21
8.1
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8
8.2.9
8.2.10
8.2.11
8.2.12
8.2.13
8.2.14
9
Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . .
Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up the Overload Protection Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up the Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cut ---in frequency of the compressor unit from ”standstill” to ”load” . . . . . . . . .
Setting up the Pressure Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faultfinding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The motor overload protection triggers after a short period . . . . . . . . . . . . . . . .
The motor overload protection triggers after a long period . . . . . . . . . . . . . . . . .
Compressor runs continuously, discharge pressure not reached . . . . . . . . . . .
Compressor cutting in too often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor shuts down, air escapes constantly at the unloading valve . . . . .
Air escapes from the unloading valve when the compressor is running . . . . . .
Unloading valve not unloading after shut ---down . . . . . . . . . . . . . . . . . . . . . . . . . .
Air escapes from the pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
---------------------------------
21
21
21
22
22
22
22
23
23
23
23
23
23
24
24
24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 25
9.1
9.2
9.3
9.4
9.5
9.5.1
9.5.2
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
Observe the following during all maintenance and servicing. . . . . . . . . . . . . . . .
Regular Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Oil Level and Topping Up (Compressor Block) . . . . . . . . . . . . . . .
Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Pressure Reducer and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean or Renew the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean or Renew the Nonreturn Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance of the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing the Unloading Valve of the Pressure Switch . . . . . . . . . . . . . . . . . . . .
Check or Renew the Cylinder Head and Valves (Compressor Block) . . . . . . . .
Checking Compressor Unit Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
-------------------------------
25
26
27
28
28
28
29
29
30
31
31
32
32
33
33
10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 34
10.1
10.2
Service Parts and Expendable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 34
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 34
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 35
11.1
11.2
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 35
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 37
ii
Technical Specification
1
Technical Specification
1.1
Compressor Unit
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECO 4 D
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 10 bar
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 kg
Air receiver:
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 l
Max. permissible gauge working pressure . . . . . . . . . . . . . . . 11 bar
Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . K1.5737.30220
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . SKK.D---00400.00
1.2
Sound Pressure Level
Operational state of the compressor unit:
Full load, the compressor unit runs at: rated speed, rated pressure, rated capacity.
Setting up conditions:
Free field measurement
Measurement to CAGI/PNEUROP PN8 NTC 2.3:
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 dB (A)
1.3
Compressor Block
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KC 350
Theoretical inlet capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 l/min
Free air delivered at 6 bar gauge working pressure . . . . . . 230 l/min
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 10 bar
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 min ---1
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 l
Oil top ---up quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1 l
1.4
Electrical Connection
Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 ± 10% V
Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 / N / PE
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz
Max. mains fusing (slowblow or gl class) . . . . . . . . . . . . . . . . 10 A
Power supply cable core cross---section . . . . . . . . . . . . . 4 x 1,5 mm2
(CU multiple core cable)
Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A
1 --- 1
Technical Specification
1.5
Drive Motor
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,7 kW
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 min ---1
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 54
Max. cut ---in frequency . . . . . . . . . . . . . . . . . . . . . . 25 times/hour
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct start
Air Main Pressure Switch Setting
Cut ---in pressure
bar
1.6
10
9
8
7
6
5
4
3
2
1
0
MDR 3/11
Possible adjustment range
of the air main pressure switch
0 1 2 3 4 5 6 7 8 9 10 11
Cut ---out pressure
bar
Works settings:
Gauge cut ---in pressure p min . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 bar
Gauge cut ---out pressure p max . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 bar
Pressure difference 'p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 bar
1.7
Safety Valve Setting
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 bar
1.8
Installation Requirements
Max. height above sea level at place of installation . . . . . . 1000 m
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 •C
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 •C
Recommended minimum compressor space size
(floor area x room height) . . . . . . . . . . . . . . . . . . . . . 10 m2 x 2,5
m
Ventilation of installation space
Inlet air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 m2
Exhaust air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 m2
1 --- 2
Technical Specification
1.9
Recommended Oil
Craftsmen’s compressors are filled with the highly suitable oils listed below:
Description
Oil sort of the
Viscosity group
VG 5, DIN 51562
maximal permissible
fluid change interval
in operating hours/
years
material
number
0.5 l
1000 / 2 *
9.4943.00010
special high perform- SAE 5 W 30
ance oil for craftsmen’s compressors
* Cool to moderate ambient temperatures, low humidity, high duty cycle
1.10
Air Receiver Charging Time
Air receiver charging time to 3 --- 8 bar 0 min 50 s
1.11
Dimensional Drawing
(see following page)
1 --- 3
Safety
2
Safety Regulations
Disregarding this notice can result in serious injury!
This manual should be read and the instructions it contains followed before initial start ---up
and before carrying out maintenance work.
The machine is constructed to the latest technological standards and to accepted safety
regulations.
Despite this fact, physical danger to the user or third parties or damage to the machine
and other property exists.
Use the machine as specified according to the service manual and only if it is in perfect
technical order!
Repair defects that could degrade safety (or have them repaired) immediately!
2.1
Explanation of Symbols and References
This symbol is placed before all regulations concerning safety where
danger to life and limb can occur during work. It is especially important that these regulations are observed and that extreme care is taken.
For their own protection, inform all other users of these safety regulations. Observe all general safety and accident prevention regulations
as well as the those laid down in this service manual.
Attention!
This symbol is placed by text where considerable attention must be
paid to recommendations, regulations, references and the correct sequence of work so that damage and/or destruction of the compressor
unit and/or other equipment is prevented.
This symbol identifies environmental care measures.
-
This symbol indicates operations and actions to be carried out by the
operator or service technician.
This bullet identifies listings.
Explanation of the warning label on the compressor unit:
Warning:
Do not touch hot surfaces.
2 --- 5
Safety
2.2
Safety Notes
Work on power-- driven equipment may only be carried out or supervised by persons trained in that particular equipment or by a specialist.
Work on electrical equipment in the compressor may only be carried
out according to electrical engineering regulations by a qualified electrician, or trained personnel under the supervision of a qualified electrician.
Before work is carried out on electrical systems, carry out the following measures in the sequence shown:
Switch off all phases.
Ensure the unit cannot be switched on again.
Check that no voltage is present.
The following actions must be carried out in the order given before
working on any pressurised parts or enclosures (e.g. pipes, vessels,
valves).
1. Shut off and depressurize all pressurized components and enclosures
2. Secure them in the depressurized state
3. Check that they are indeed de -- pressurized
Attention!
Any alterations or reconstruction carried out without consultation with
and the previous consent of KAESER COMPRESSORS will invalidate
the warranty.
Safety devices may not be modified or deactivated.
Signs and marks of reference may not be removed or rendered unreadable.
We also recommend observation of the following:
-
-
Allow no open flame and flying sparks in the place of installation.
During any necessary welding on the compressor unit or nearby ensure that sparks or
high temperatures cannot cause fire or explosion.
Ensure that the compressor unit is supplied with clean air free of damaging components.
The ambient temperature should not rise above or fall below the limits defined in
chapter 1.8. If this is the case, special measures must be agreed between the manufacturer and the user.
The oil change must be carried out according to the service manual, or at least once
annually.
This machine is not explosion ---proof.
It may not be operated in areas in which specific requirements with regard to explosion protection are applied.
These are, for example, the requirements for “specified use in hazardous explosive
environments” according to the 94/9/EU ATEX Directive.
2 --- 6
Safety
2.3
Electrical Safety
Attention!
The electrical system of a compressor unit must comply with the provisions of the European Standards EN 1012 -- 1 and EN 60204 -- 1) and,
if necessary, with the local electricity supply authority regulations.
Compressor units must be fitted with a main isolating device, the operation of which determines the start and end of the energy supply.
Main isolating devices can be main switches or plug and socket connections.
For this reason the following measures must be taken at the place of
installation:
Compressor units fitted with a drive motor of drive power 3 kW or
more and a current rating of 16 amperes or more must be fitted with a
lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses.
The main switch must be designed according to the maximum rated
current I N (see chapter 1.4).
See chapter 1.4 for details of the cable cross-- sections and mains
fuses.
Compressor units fitted with a drive motor of drive power less than
3 kW and a current rating of less than 16 amperes may be fitted with a
mains plug connection.
2.4
Spare Parts
Safe and reliable operation of the compressor unit is guaranteed only with KAESER original
spare parts.
2.5
Environmental Protection
Condensate drainage
Condensate accumulating during compression must be drained via a
suitable draining system and collected in disposal canisters. The condensate must be disposed of according to environmental regulations.
Operational and repair materials, used parts
Dispose of all used materials and parts accumulating during operation, maintenance and repair of the compressor unit according to
environmental care regulations!
Disposing of the Machine
When disposing of a machine, drain out all liquids and remove dirty filters.
Any parts contaminated with oil must be disposed of in accordance
with local environment regulations.
Take the machine out of service (see chapter 8.1).
Drain all oil completely from the machine (see chapter 9.6).
Remove dirty filters.
Use the services of an approved local disposal specialist to ensure environmentally correct
disposal of the empty machine.
2 --- 7
General
3
General
Attention!
3.1
The service manual must always be available at the compressor unit’s
place of use
Correct Use of the Compressor
The compressor unit is intended solely for the purpose of generating compressed air. Any
other use is considered incorrect. The manufacturer cannot accept liability for any damage
caused by such incorrect use; the user alone is liable for any risks incurred.
Correct use of the compressor also encompasses compliance with the installation, removal, commissioning, operational and maintenance conditions laid down by the manufacturer.
The machine is intended solely for industrial use and application in industrial facilities. Any
other use or application is forbidden. The manufacturer is not liable for any damages resulting from such unspecified use or application. The user or operator alone bears the risk for
such damages.
This applies especially to the obligation
3.2
-
to become acquainted with the fundamental safety regulations that apply
to compressed air engineering
-
to refuse access to the machine by persons under the age of fourteen, and
-
to have the technical condition of the machine inspected within the intervals
prescribed for industrial use.
Incorrect Use
Never direct compressed air toward persons. Compressed air is a concentrated form of energy and as such is dangerous to life.
3.3
Compressed Air Treatment
Never use compressed air for breathing purposes and production
methods where the air has direct contact with food without subjecting
the compressed air to additional treatment.
3.4
Copyright
The copyright of this service manual is the property of the KAESER Company. This service
manual is intended for operating personnel, maintenance personnel and supervisory personnel use only. It contains instructions and technical diagrams that may not be copied,
either completely or partly, distributed or evaluated by unauthorised persons for the purpose of competition, or divulged to any other third party.
3.5
Accompanying Documents
With this Service Manual are documents intended to assist in safe and sure operation of
the compressor:
-
Certificate of acceptance / operating instructions for the pressure vessel
-
Conformity or Manufacturer’s Declaration in accordance with applicable directives
Make sure all documents are to hand and their contents understood.
Request the supply of any missing documents from KAESER.
Make sure you give the data from the nameplate.
3 --- 8
Transport
4
Transport
4.1
Transport Instructions
To prevent damage, always transport the compressor unit with the help of a forklift truck,
lift truck or a sling.
See chapter 1.1 for details of the weight.
4.2
Transport with a Fork Lift Truck or Lift Truck
Always mount the compressor unit on a suitable transporting medium (pallet or wooden
base) when transporting with a fork lift truck or lift truck.
Attention!
Never drive directly underneath and lift. There is danger of tipping because of the high point of gravity!
4 --- 9
Transport
4.3
Transport Using a Crane
Attention!
If the compressor unit is transported by a crane the safety regulations
concerning lifting appliances must be observed.
Do not stand underneath hanging loads.
Do not exceed the max. permissible lifting weight of the lifting appliance.
Always use a sling when transporting the compressor unit with a crane.
Attention!
4.4
Take care not to damage the condensate drain valve on the air receiver
when fitting the sling.
Packaging
A decisive factor in the type of packaging is the transport route.
The packaging conforms to packaging regulations laid down by the German Federal Association of Wood, Pallet and Export Packaging (HPE), and by the German Machinery and
Plant Association (VDMA), if not otherwise contractually agreed.
For transport purposes, the compressor unit is mounted on a strengthened base within a
wooden framework.
Attention!
Retain the wooden framework and strengthened base for possible
transport of the compressor unit at a later date.
Remove the wooden base at the point of installation by unscrewing the four bolts (see
chapter 6.2).
4.5
Storage
Always store the compressor, whether packaged or not, in an enclosed dry space.
The ambient temperature may not exceeds the limits of --- 25 •C and + 60 •C.
4 --- 10
Construction and Operation
5
Construction and Operation
Items in ( ) refer to components with item number in the schematic diagram of the compressor unit (see chapter 5.4).
5.1
Principle of Compression
This reciprocating compressor is an air cooled, oil lubricated compressor using the principle of single stage compression
Atmospheric air is drawn into the compression chamber of the compressor block (2)
through the air filter (1). Air is drawn in via the valve plate in the cylinder head during the
downward motion of the piston from the top to the bottom dead centres. After the piston
has reached the bottom dead centre position the air is compressed within the cylinder by
the upwards motion of the piston. Simultaneously the inlet valves in the valve plate close
and the discharge valves open.
The compressed air now enters the air receiver (4) via a nonreturn valve (3). The nonreturn
valve prevents the compressed air from flowing back into the compressor block when the
compressor unit is stopped.
5.2
Short Description
The compressor block is driven by an electric motor (7). The compressor block is directly
coupled to the motor via the motor shaft.
The end of the motor shaft is designed as a crankshaft. A fan supplying the necessary
cooling air for the motor and the compressor block is fitted to the N---end of the motor
shaft. The heat generated is dissipated via the cooling fins on the cylinder and the cylinder
head.
The crankshaft is supported by roller bearings; the connecting rod is supported by shell
bearings. The cylinder liner, piston, crankshaft and connecting rod are automatically splash
lubricated.
To enable an unloaded start the pressure switch (6) is fitted with an unloading valve.
A nonreturn valve (3) is fitted upstream of the air receiver (4) to prevent compressed air
flowing back from the air receiver.
The air receiver (4) is constructed to the regulations of the pressure vessels act and fitted
with all necessary fittings such as safety valve (5), pressure gauge (8), pressure switch (6)
and nonreturn valve (3).
5.3
Compressor Control (Stop ---Start Control)
The compressor is controlled by the pressure switch.
After the compressor is first switched on the pressure switch switches the compressor, depending on the air demand, between the two operating states ”load” and ”standstill”
within the limits p min / p max.
See chapter 1.6 for the works setting of the pressure switch.
The compressed air pipe from the compressor block up to the nonreturn valve is vented
when the cut ---out gauge pressure is reached to ensure an unloaded compressor start.
5 --- 11
Construction and Operation
5.4
Components of the Compressor Unit
12
11
9
10
1
2
7
14
3
8
6
5
4 13
1 Air filter
cleans
the inlet air
8
Pressure gauge
indicates the current pressure
in the air receiver
2 Compressor block
draws in the air and compresses
it to the discharge pressure
9
Oil level sight glass
3 Nonreturn valve
prevents the compressed air from
flowing back into the block
10
Oil filler with crankcase venting
plug
4 Air receiver
compressed air tank and
accumulation of condensate
11
Oil drain plug
5 Safety valve
12
protects the air receiver, blows off
if the max. working pressure is exceeded
Compressed air discharge connection
to the air mains
6 Pressure switch
controls compressor stop and start
13
Condensate drain cock
7 Electric motor
drives the compressor block;
Fan on N shaft end provides
the necessary cooling air
14
Direction arrow on the fan guard
5 --- 12
Installation
6
Installation
6.1
Installation Instructions
To ensure sufficient cooling of the compressor unit the specified minimum compressor
space size, minimum distance to the walls and minimum size of the ventilation inlet and
exhaust openings must be complied with (see chapter 1.8).
The cooling air flow of the compressor unit is not greatly influenced in smaller spaces even
if the door is opened, if the air flowing in through the door takes the shortest route to the
exhaust opening without flowing around the compressor.
Safe operation of the compressor unit is only guaranteed if the ambient temperature remains within the limits stated in chapter 1.8.
Exhaust
opening
800*
500
Inlet opening
Dimensions in mm
* Recommended
minimum door
width to allow
entry of
compressor
6 --- 13
Installation
6.2
Fitting the Antivibration Mounts
The antivibration mounts supplied with the compressor unit (as a separate package fixed
to the compressor block) must be fitted before the compressor is first put into operation.
Attention!
Use transporting belts to lift the compressor unit. Observe the instructions in chapter 4.3.
The compressor can tip because of its own weight and high point of
gravity.
Attention!
The antivibration pads must be fitted according to the arrangement
shown in the following diagram.
2
1
1
1
1 Antivibration mount
soft (40 Sh) 4.1493.0
2
Antivibration mount
hard (90 Sh) 4.1476.0
6
5
4
1
3
2
1 Antivibration mount
2 Fastening bolts
3 Wooden base
6.3
4
5
6
Washer
Spring washer
Hexagonal nut
Lift up the compressor unit with the transport belt. Observe the instructions in chapter 4.3.
Unscrew the bolts (4) and remove the wooden base (3) from the feet of the air receiver.
Fit the antivibration mounts (1) with washers (4), spring washer (5) and hexagonal bolt
to the feet of the air receiver.
Connection of the Compressed Air Supply
The compressor unit is piped ready for use. Connect the discharge outlet to the air main
using a flexible hose.
6 --- 14
Installation
6.4
Electrical Connection
The connection to the power supply and the protective measures
necessary are to be carried out to the provisions of the European Standards EN 1012 -- 1 and EN 60204 -- 1 and to the regulations of the
local Electricity Supply Authority by an authorised electrician.
Attention!
For this reason, the following measures must be carried out at the
place of installation:
Compressor units fitted with a drive motor of drive power 3 kW or
more and a current rating of 16 amperes or more must be fitted with a
lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses.
Compressor units must be fitted with a main isolating device, the operation of which determines the start and end of the energy supply.
Main isolating devices can be main switches or plug and socket connections.
The main switch must be designed to according to the maximum rated
current I N (see chapter 1.4).
Compressor units fitted with a drive motor of drive power less than
3 kW and a current rating of less than 16 amperes may be fitted with a
mains plug connection.
-
The electrical installation of the compressor unit must be carried out according to the
electrical diagram (see chapter 11.1). The connection to the power supply is made
with a mains plug.
Attention!
The supply cable and fuses are selected to DIN VDE 0100, sect. 430
and 523 for an ambient temperature of 30 •C. Under other
operating conditions such as a higher ambient temperature or longer
supply cables (longer than 50 metres) the cross-- section of the supply
cables and the fuses must be checked and selected according to DIN
VDE 0100 and to the regulations of the local electricity supply authority.
See chapter 1.4 for details of the cable cross-- sections and mains
fuses.
6 --- 15
Initial Start
7
Putting into Operation
7.1
Points to be Observed before Putting into Operation
Every compressor unit is given a test run in the factory and carefully checked before shipment. The test run confirms that the compressor unit conforms to the specification data
and runs perfectly. However, independent of the checks made at the factory, the compressor unit could be damaged during transport. For this reason, we recommend that the
compressor unit is examined for such possible damage. Observe the compressor unit
carefully during the first hours of operation for any possible malfunction.
Attention!
Work on power driven systems may only be carried out by trained or
specialised personnel.
Work on the electrical system and equipment of the compressor unit
may only be carried out by a skilled electrician or by instructed personnel under the supervision and guidance of a skilled electrician and
in accordance with electrical engineering rules and regulations.
Attention!
Important functional components in the compressor unit such as the
nonreturn valve and safety valve are set up and fitted at the factory to
precise setting up regulations. Changes are not permitted without
previous consultation with KAESER.
The nonreturn valve and the safety valve are spring loaded.
Points to be observed before starting the compressor unit:
ANY NON -- OBSERVANCE OF THESE OR OTHER REFERENCES
(WARNING; ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.
The compressor unit restarts automatically after a power failure provided the air main pressure is lower than the cut-- out pressure level
set on the air main pressure switch.
7.2
-
It is expected that the operator employs safe working methods and that all valid and, if
necessary, all local operating and safety regulations are complied with when operating
the compressor unit.
-
The user of this compressor unit is responsible for its safe operating condition.
-
Do not operate this compressor unit in spaces where high dust pollution, poisonous or
inflammable vapours or gases could exist.
-
Do not connect the compressor unit to a supply voltage other than that stated on the
nameplate.
-
Do not install the compressor unit in a space subject to freezing temperatures,
whereby the air temperature conditions at the compressor’s air inlet must be complied
with (see chapter 1.8).
-
Check the level of the oil in the compressor block. If necessary, top up according to
the oil recommendations (see chapter 1.9).
Direction of Rotation Check
-
Check the direction of rotation by switching on the compressor for a short period. If
the direction of rotation does not coincide with the arrow located on the fan guard,
change over terminals L1 and L2.
7 --- 16
Initial Start
7.3
Setting up the Overload Protection Trigger
Before any adjustments are carried out to the compressor package
break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Attention!
Three -- phase motors may be only be run with a correctly adjusted
overload protection trigger.
The motor overload protection trigger is set at the factory with the standard setting.
Compressor drive motor: direct on-- line start
The compressor unit starts directly on line and is controlled by a pressure switch combination. The pressure switch switches the compressor unit on and off within preset pressure
limits and the integral thermal overload protection trigger ensures that the compressor unit
is shut down if the current flowing exceeds the preset value.
Setting: rated motor current (see motor nameplate).
The setting can be up to 10% higher than the rated motor current to prevent voltage fluctuations triggering the overload protection trigger.
If the thermal overload protection has triggered and shut down the compressor unit the
ON/OFF switch switches to the ‘‘OFF’’ position. Start the compressor unit again by setting
the switch to the ‘‘AUTO’’ position.
Attention!
If the compressor unit does not immediately start, wait until the drive
motor has cooled down.
If the motor overload protection triggers several times in sequence,
other causes maybe responsible for triggering the overload protection
(e.g. low insulation of the motor windings or cables, seized motor.) If
this occurs, have a specialist check the compressor and motor to find
the cause of the problem.
3
2
1
5
4
1 Cover
2 Dial
3 Mark ( )
4
5
ON/OFF switch
Screw
If necessary adjust the motor overload protection trigger setting as follows:
Shut down the compressor.
7 --- 17
Initial Start
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Loosen the screws (5) to the right and left of the cover (1).
Remove the cover (1) of the pressure switch.
Turn the dial (2) with a screwdriver so that the mark ( ) coincides with the value of the
rated motor current on the dial (2).
Replace the cover (1) after every adjustment of the pressure switch
and before starting the compressor unit.
7.4
Replace the cover (1).
Setting up the Pressure Switch
Break the power supply by operating and locking out the main isolating device (main switch or mains plug, see chapter 2.3) to prevent an
accidental compressor start before any adjustments are carried out to
the compressor unit.
See chapter 1.6 for the factory setting of the pressure switch and the pressure diagram.
Attention!
The pressure setting can only be changed with the pressure switch
fitted and under pressure.
Attention!
Do not set the maximum cut-- out pressure higher than the maximum
gauge working pressure (see chapter 1.1).
5
1
3
4
2
+
p
---
1
2
3
4
5
+
---
Cover
Screw
”Upper switching point” (Cut ---out pressure) adjusting screw
Pressure difference adjusting screw
ON/OFF --- Switch (OFF/AUTO)
Shut down the compressor unit (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
7 --- 18
Initial Start
Unscrew the screws (2) to the right and left of the cover (1).
Remove the cover (1) of the pressure switch.
Carry out the adjustment of the pressure switch.
Replace the cover (1) after every adjustment of the pressure switch
and before starting the compressor unit.
Replace the cover (1).
To increase the cut-- out pressure:
Turn the screw (3) clockwise in the ”+ ”direction.
To decrease the cut-- out pressure:
Turn the screw (3) counterclockwise in the ” ---” direction.
To increase the pressure difference between the cut-- in and cut-- out pressures:
Turn the screw (4) clockwise in the ”+ ” direction.
To decrease the pressure difference between the cut-- in and cut-- out pressures:
7.4.1
Turn the screw (4) counterclockwise ” ---”direction.
Cut-- in frequency of the compressor unit from ”standstill” to ”load”
The cut ---in frequency of the compressor unit from ”standstill” to ”load” can be changed
within a limited range by changing the switching difference. To change the cut ---in frequency the pressure switch must be adjusted (see chapter 7.4).
Attention!
7.5
See chapter 1.5 for the maximum cut-- in frequency from ”standstill” to
”load” per hour.
-
Increasing the switching difference causes a decrease in the cut ---in frequency.
-
Decreasing the switching difference causes an increase in the cut ---in frequency.
Setting up the Pressure Reducer
The working pressure of a compressor unit fluctuates according to the pressure limits set
on the pressure switch (see chapter 1.6).
The pressure reducer reduces this fluctuating working pressure to the working pressure
required and holds it constant.
1
2
4
3
1
2
3
4
Regulating screw
Locking nut
Pressure gauge (working pressure)
Compressed air discharge
7 --- 19
Initial Start
Switch on the compressor unit and allow it to run without any consumers until the
cut ---out pressure is reached.
Turn the regulating screw (1) anticlockwise until no more resistance is felt. This
measure unloads the pressure reducer.
Turn the regulating screw (1) clockwise until the required pressure is indicated on the
pressure gauge (3).
Lock the regulating screw (1) to this position with the locking nut (2).
7 --- 20
Operation
8
Operation
8.1
Starting and Stopping the Compressor Unit
Starting the compressor unit
Operate the main isolating device (main switch or plug, see chapter 2.3).
1
1 ON/OFF switch
‘‘0’’ position = OFF
‘‘l’’ position = AUTO
Switch on the compressor unit at the pressure switch (turn switch to position ‘‘l’’).
Shutting down the compressor unit
8.2
Switch off the compressor unit at the pressure switch (turn switch to position ‘‘0’’).
Operate and lock out the main isolating device to isolate the compressor from the
mains power supply.
Faultfinding and Removal
General safety regulations (see chapter 2) and local safety regulations
must be complied with during faultfinding and removal procedures.
Starting after a defect:
See chapter 7 ‘Putting into Operation’.
Explanation of symbols for the following fault diagnosis:
% 1 --- have checked by a specialist.
% 2 --- contact KAESER customer service department.
8.2.1
Compressor does not start
Possible cause:
Remedy:
No motor power supply, fuses blown.
Replace the fuses; % 1.
Contact in pressure switch defective.
Renew the pressure switch; % 1.
Motor overload protection triggered.
Check the setting (see chapter 7.3); % 1.
8 --- 21
Operation
8.2.2
Compressor starts with difficulty
Possible cause:
Remedy:
Unloading valve at the pressure switch not
opening.
Renew the unloading valve (see chapter
9.11); % 1.
Damaged bearings.
Renew the bearings or fit an exchange
compressor; % 2.
Pistons siezed
(no oil or wrong oil).
Power supply fault (2---phase running).
Oil level too high.
8.2.3
8.2.4
8.2.5
% 2.
Check the power supply (fuses); % 1.
Reduce the oil level to the maximum mark
on the oil level sight glass (see chapter 9.3).
Compressor overheating
Possible cause:
Remedy:
Ambient temperature too high
(over 40 •C).
Lower the ambient temperature (see chapter 1.8).
Wrong direction of rotation
(observe the direction arrow).
Change over L1 and L2 terminals (see
chapter 7.2); % 1.
The fan cannot draw in air freely.
Ensure that inlet air is available for the fan.
Valve plate leaking, coked or the valve
reeds are broken.
Check, decoke or renew valve plate; % 1
and % 2.
The motor overload protection triggers after a short period
Possible cause:
Remedy:
Power supply fault (2---phase running).
Check the power supply (fuses); % 1.
Defective motor.
Change the motor; % 1 und % 2.
The motor overload protection triggers after a long period
Possible cause:
Remedy:
Setting too low.
Check the setting (see chapter 7.3); % 1.
Current too high because of low supply
voltage.
Check the cross---section of power supply
cable (see chapter 6.4); % 1.
Check the power supply terminals;
tighten the screws.
8 --- 22
Operation
8.2.6
Compressor runs continuously, discharge pressure not reached
Possible cause:
Remedy:
Air filter clogged.
Clean or renew the air filter
(see chapter 9.7); % 1.
Valve plate leaking, coked or valve reeds
broken.
8.2.7
8.2.8
8.2.9
8.2.10
8.2.11
Check, decoke or renew valve plate; % 1
and % 2.
Pressure losses within the unit.
Brush soapy water on piping and fittings,
seal leaks, renew leaking parts; % 1.
Air demand higher than the capacity of the
compressor.
Extend the compressed air supply.
Losses at the consumer / in the air main.
Check for possible leakage points.
Compressor cutting in too often
Possible cause:
Remedy:
Air receiver filled with condensate up to the
discharge cock.
Drain the condensate (observe environmental care regulations), carry out routine maintenance regularly (see chapter 9.4); % 1.
Compressor shuts down, air escapes constantly at the unloading valve
Possible cause:
Remedy:
Defective nonreturn valve.
Renew the seal or renew the valve cone
(see chapter 9.8); % 1.
Air escapes from the unloading valve when the compressor is running
Possible cause:
Remedy:
Unloading valve not closing (dirty or defective).
Renew the unloading valve
(see chapter 9.11); % 1.
Unloading valve not unloading after shut-- down
Possible cause:
Remedy:
Dirty unloading valve.
Renew the unloading valve
(see chapter 9.11); % 1.
Air escapes from the pressure switch
Possible cause:
Remedy:
Defective diaphragm.
Renew the pressure switch; % 1.
Unloading valve does not close.
Renew the unloading valve; % 1.
8 --- 23
Operation
8.2.12
8.2.13
8.2.14
Whistling noises at the cylinder head
Possible cause:
Remedy:
Loose cylinder head bolts or defective gaskets.
Tighten the bolts or renew the gaskets; % 1
and % 2.
Safety valve blowing off prematurely
Possible cause:
Remedy:
Safety valve blows, even though the cut --out pressure is not yet reached.
Check that the pressure gauge functions
correctly, replace if necessary.
Check the pressure setting.
Defective valve spring.
Renew the safety valve; % 1.
Safety valve was opened, dirt particles
stuck in valve seat.
Open the safety valve completely for a short
period to allow it to blow itself clean.
Oil consumption of compressor too high
Possible cause:
Remedy:
Viscosity of oil too low.
Fill with correct oil
(see chapter 1.9); % 1.
Defective crankcase venting plug.
Clean or renew the crankcase venting plug;
% 1.
Piston rings worn or damaged.
Piston rings worn or damaged after only a
short period.
Renew piston rings and cylinder; % 2.
Renew piston rings and cylinder; % 2.
(ensure that the inlet air is clean, e.g. by
using an air filter with a higher grade of filtration).
8 --- 24
Maintenance
9
Maintenance
9.1
Observe the following during all maintenance and servicing.
Disregarding these notes and/or improper handling may result in serious injury.
Work on power-- driven equipment may only be carried out or supervised by persons trained in that particular equipment or by a specialist.
Work on electrical equipment in the compressor may only be carried
out according to electrical engineering regulations by a qualified electrician, or trained personnel under the supervision of a qualified electrician.
Before starting any maintenance work switch off at the main switch
and lock off to secure against unwanted or accidental switching on.
The complete machine must be depressurised before opening or removing any pressure -- retaining components.
Check all machine hose connectors with a hand -- held pressure gauge
to ensure that all read 0 bar.
Make sure the machine is shut-- off or isolated from the air main during
maintenance work to ensure that no compressed air flows back from
the main.
Before switching on again ensure that all maintenance personnel are
clear of the machine, that all panels are replaced and all access doors
closed.
The following points must be observed when handling lubricating and
cooling materials:
Avoid contact with skin and eyes.
Do not inhale vapours and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.
Ensure that all lubricants, consumable materials and replacement
parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental regulations.
9 --- 25
Maintenance
9.2
Regular Maintenance Work
Interval
Maintenance tasks
see chapter
Daily
Check the crankcase oil level.
9.3
Drain condensate from the air receiver.
9.4
Drain condensate from the pressure regulator
9.5
Check all electrical terminals and tighten if
necessary.
7.1
Change the compressor oil
9.6
Check and clean the air filter *
9.7
Check and clean the check valve *
9.8
Check the pressure relief valve
9.9
Every 1000 h
at least every 2 years
Change the compressor oil *
9.6
Every 3,000 h
Check correct function of the cylinder head and
valves
9.12
Every 10,000 h
Change the motor bearings
9.10
Carry out a general compressor overhaul
9.12
50 h after initial
start ---up
Every 500 h
At least once a year
* Maintenance interval may change depending on model,
installation, motor starting frequency and ambient conditions.
It is recommended that a log is kept of maintenance work done.
See chapter 11.2 for a sample list of maintenance tasks.
9 --- 26
Maintenance
9.3
Checking the Oil Level and Topping Up (Compressor Block)
Check the oil level at the oil level sight glass daily and before each start.
Attention!
If the oil level has sunk to the lower mark, top up the oil immediately
according to the oil recommendations (see chapter 1.9).
Never top up to a level exceeding the maximum oil mark on the oil
level sight glass.
Attention!
When topping up the oil always use a strainer or pour the oil directly
from the new oil can.
1
max.
min.
2
2
1 Oil filler with crankcase venting plug
2 Oil level sight glass
Shut down the compressor (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Remove the crankcase venting plug (1) from the oil filler.
Attention!
As the oil must flow through the crankcase first, the maximum oil level
is reached after a few minutes have elapsed.
Fill with oil until the maximum oil level mark is reached. See chapter 1.3 for the quantity of oil required for topping up from the minimum mark to the maximum mark.
Replace the crankcase venting plug in the oil filler.
9 --- 27
Maintenance
9.4
Air Receiver
Attention!
The provisions of the Pressure Vessels Act must be conformed with.
The relevant regulations of the country concerned must also be observed.
Drain the condensate collecting in the air receiver daily with the condensate drain valve (1).
Drain the condensate into a suitable container and dispose of according to environmental care regulations!
1
1 Condensate drain cock
9.5
Cleaning the Pressure Reducer and Filter
9.5.1
Condensate drainage
Drain the condensate regularly, at least daily.
Drain the condensate into a disposal canister and dispose of according to environmental care regulations.
Loosen the knurled screw (1) using an Allen key and drain off the condensate into a
disposal canister.
Tighten the knurled screw (1) again using an Allen key.
2
3
1
1 Knurled nut with Allen key socket
2 Clamping ring
3 Label for cleaning agent instructions
9 --- 28
Maintenance
9.5.2
Cleaning the filter
Shut down the compressor unit (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Drain the condensate (see chapter 9.5.1).
Remove the filter bowl by unscrewing the clamping ring (2).
Take out and clean the O---ring.
Attention!
Clean the filter bowl.
Attention!
9.6
Observe the instructions concerning the cleaning agent stated on the
label (3) attached to the filter bowl.
Take care that the O -- ring is correctly seated during reassembly.
Screw the filter bowl back on again.
Oil Change (Compressor Block)
Change the oil with the compressor unit at normal operating temperature.
Danger of scalding by hot oil
Danger of burns from hot components
Change the oil after approximately the first 50 service hours.
Change the oil futher: see chapter 9.2.
If, under unsuitable operational conditions condensed water is observed in the oil, recognisable by the milky colour in the oil level sight gauge (2), carry out an oil change immediately.
1
2
3
1 Oil filler
2 Oil level sight glass
3 Oil drain plug
Shut down the compressor (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Remove the crankcase venting plug (1) from the oil filler.
Prepare a container to catch the oil.
9 --- 29
Maintenance
Collect the used oil and dispose of according to environmental care
regulations!
Unscrew the oil drain plug (3) and drain the oil into the container.
Flush out the crankcase with a small quantity of new oil.
Screw the oil drain plug back into the crankcase.
Attention!
9.7
When topping up the oil always use a strainer or pour the oil directly
from the new oil can.
Fill up with new oil (see chapter 9.3).
Clean or Renew the Air Filter
The filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre.
Clean the filter cartridge (3) at the latest after 500 service hours. If the cartridge is heavily
contaminated or has been cleaned often, renew the air filter complete.
2
1
3
4
1
2
3
4
Air filter
Air inlet
Filter cartridge
Spring clips
Shut down the compressor (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Unscrew the air filter (1) from the cylinder head.
Unhook the spring clips (4) and open the filter cap.
Attention!
Clean the filter with diesel fuel in the open air. Observe the regulations
concerning the handling of combustible fluids.
Clean the filter cap, especially the sealing surfaces.
Wash out the filter cartridge (3) with diesel fuel or clean with a steam jet.
When the filter cartridge (3) is dry wet lightly with oil.
Attention!
When screwing on the air filter take care that the air inlet in the filter
cap (2) is facing downwards.
Screw on the air filter (1), fit the cap.
Attention!
If the cartridge is heavily contaminated or has been cleaned often,
renew the air filter complete.
9 --- 30
Maintenance
9.8
Clean or Renew the Nonreturn Valve
The nonreturn valve is fitted to the inlet port of the compressed air line on the air receiver. It
prevents the compressed air flowing back from the air receiver into the compressor block.
Check and, if necessary, clean the nonreturn valve every 500 service hours.
6
5
2
1
4
3
1 Nonreturn valve
2 End plug
3 Valve cone
4
5
6
Valve seat
Spring
Sealing ring
Shut down the compressor (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Isolate the compressor unit from the air main (close the user’s shut ---off valve).
Vent the air receiver with the condensate drain cock (see chapter 9.4).
Do not open the end plug in the valve housing until the pressure gauge
indicates zero.
9.9
Unscrew the end plug (2) in the valve housing.
Clean the valve cone (3) and valve seat (4).
Renew the valve cone (3), the spring (5) and the sealing ring (6) if they are heavily
worn or damaged.
Reassemble in the reverse order.
Checking the Safety Valve
If the maximum permissible gauge working pressure in the air receiver is exceeded, the
safety valve (2) opens and blows off the excess air to protect the compressor unit and the
consumers connected to the air mains.
To prevent the valve seat from sticking, open the safety valve every 500 service hours or at
least annually.
1
2
1 Knurled ring
2 Safety valve
9 --- 31
Maintenance
Attention!
It is essential to wear ear protection when testing the pressure relief
valve because of the loud noise produced by escaping air.
Switch the compressor off (see chapter 8.1).
Isolate from the power supply by means of the main switch or by withdrawing the mains plug and lock out the switch to prevent an inadvertent start.
9.10
Turn the knurled screw on the pressure relief valve anticlockwise until air escapes and
then turn back again.
Attention!
A defective pressure relief valve must be renewed completely.
Attention!
Tampering with the pressure relief valve and damaging the lead seal is
forbidden and will invalidate all liability.
Maintenance of the Motor Bearings
-
The motor bearings are permanently greased.
Under normal operating conditions, with ambient temperatures around 25 •C, the
motor bearings should be renewed approximately every 10 000 service hours.
-
The wear on the bearings increases with higher ambient temperatures. With very high
ambient temperatures of around 35 •C renew the bearings approximately every 6000
hours.
-
Change the motor bearings every 3 years independent of service hours.
Attention!
9.11
The bearings must be changed by KAESER-- Service when the above
maintenance is due.
Renewing the Unloading Valve of the Pressure Switch
If a dirty unloading valve causes the compressor unit to start with difficulty, it must be renewed.
1
1
2
1 Unloading valve
2 Hex socket head bolt
Shut down the compressor unit (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
9 --- 32
Maintenance
9.12
Isolate the compressor unit from the air main (close the user’s shut ---off valve).
Vent the air receiver with the condensate drain valve (see chapter 9.4).
Unscrew the hoses from the pressure switch.
Unscrew the hex socket head bolt (2) and take out the unloading valve (1).
Fit a new unloading valve.
Start the compressor unit (see chapter 8.1).
Check for leaks, e.g. brush on soapy water.
Check or Renew the Cylinder Head and Valves (Compressor Block)
Check the cylinder head and the valves for correct function after 3000 service hours.
Attention!
If faults are obvious on the cylinder head or the valves, these parts
must be repaired or renewed by KAESER Service.
Have the compressor generally overhauled by KAESER Service after 10000 service hours.
9.13
Checking Compressor Unit Performance
The effective compressor unit performance can be determined by measuring the charging
time of the air receiver.
Shut down the compressor unit (see chapter 8.1).
Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.
Isolate the compressor from the air main (close the user’s shut ---off valve).
Vent the air receiver with the condensate drain cock and then close the cock again
(see chapter 9.4).
Close the shut ---off valve on the air receiver.
Start the compressor unit (see chapter 8.1) and simultaneously measure and compare
the charging time taken to achieve the gauge pressure stated in the technical specification (see chapter 1.10).
9 --- 33
Spare Parts and After Sales Service
10
Spare Parts and After Sales Service
10.1
Service Parts and Expendable Parts
Name
No. off
Part number
Air filter
1 off
6.0173.1
Nonreturn valve
1 off
8.0263.3
KAESER KOMPRESSOREN GmbH
Carl--- Kaeser--- Str. 26, 96450 Coburg
GERMANY Telefon + 49 95 61 64 00
Fax + 49 95 61 01 30
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Year of production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. working press. (g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Free air delivered . . . . . . . . . . . . . . . . . . . . . l/min . . ( . . . bar)
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rated motor speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW
Ambient temperature . . . . . . . . . . . . . . . . . . C / . . . . . . . .
10.2
C
Ordering Spare Parts
When ordering spare parts always state (see nameplate):
--- Compressor model
--- Year of manufacture
--- Part number
--- Serial number
Important for all queries:
Enter the data from the nameplate of the compressor unit in the nameplate illustrated
above.
Always quote the data on the nameplate when ordering spare parts or making enquiries.
Attention!
Do not fit inferior consumable or spare parts. Use only original parts
supplied by the compressor manufacturer.
We must point out that maintenance parts, spare parts and accessories not delivered by
KAESER are also not tested and cleared by us. The fitting and/or use of such products
can, under certain circumstances, change the design characteristics of the compressor
unit negatively and therefore affect the active and/or passive safety of the unit.
The use of such parts or accessories exempts KAESER from all liabilities and warranties for
consequential damage caused by such parts or accessories.
10 --- 34
Appendix
11
Appendix
11.1
Electrical Diagram
(see following page)
11 --- 35
Appendix
11.2
Maintenance Record
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date
Description of work
Operating hours
Signature
11 --- 37
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