Reciprocating Compressor Model: KCD 125 — 100 Part No.: 1.9568.0 Serial No, Index: 060301 GL-Nr: KCD125- 100-1.3568.0-01 Manufacturer: KAESER KOMPRESSOREN GmbH 96410 Coburg + PO Box 2143 + GERMANY « Tel. +49-9561-6400 » Fax +49-9561 -640130 http://www.kaeser.comC € DECLARATION OF CONFORMITY within the meaning of Machinery Directive 98/37/EC, Anex II We hereby declare that the machine: ‘Type designation: KCD 125 - 100 Material No. 135680 Safa Nos in the specification supplied by us conforms to the following relevant provisions, in particular: 9e/37/EC Machinery Directive ‘73/23/EEC Low Voltage Directive 87/404/EEC Simple Unflred Pressure Vessels Directive 89/336/EEC ——_ Electromagnetic Compatibility Directive The following harmonized standards are applied: EN 1012-1: 1996 > DIN EN 1012 DIN EN 292-1: DIN EN 292-2/A1: 1995-06 DIN EN 294; 1991-08 DIN EN 60204-1: 1998-11 vvvy The following standards are applied for evaluation of electromagnetic compatibility: > DIN EN 55014: 1993 - 12 EN 55014-1: 1993 ‘The following national standards, directives and specifications are applied: > German National Equipment Safety Act > German National Equipment Safety Act Regulation — Coburg 01.12.1999 Location ate re KAESER KOMPRESSOREN GmbH Tel: (09681)6400 _Exmoutves: Opin Cat Kaas, Dpl-W-ing. Thomas Kaeser Cat Kaes0r-St. 28, 86450 Coburg Fax (095 61) 640-130 Court of Jurisdiction: Coburg B 282 Germany ‘The 689.268 YVATNo. DE 132460821Uta] easels Table of Contents Chapter ~ Page 1 Technical Specification . -1-1 1.1 Compressor Unit ........00cecsre see 7 1-1 1.2 Sound Pressure Level 1-1 1.8 Compressor Block .......... 1-1 1.4 Electrical Connection ..... 1-2 iG ee Drive) Motocherecereeese eee treet 1-2 1.6 Air Main Pressure Switch Setting .............00:00etecceeecerees 1-2 1.7 Safety Valve Setting . : wees wee 1-2 1.8 Installation Requirements cee ttetteerteeenses 1-3 1.9 Recommended Oils .....-...-- 2.00 eeeeeseceeeeeeeeeeesees 1-3 1.10 Air Receiver Charging Time... 2.5.6.0... oe eeeeeeeeeees 1-3 1.11. Dimensional Drawing .......... 1-3 2 Safety Regulations ... 2-4 2.1 Explanation of Symbols and References 2-4 2.2 — General Safety Precautions 2-4 23 Electrical Safety ............ 2-5 24 — General References 2-6 25 Spare Parts . cece a 2-6 2.6 — Compressed Air Installation ..... eee 2-6 2.7 Environmental Protection ..........ccccceeeseeseeeeeeee 2-6 3 General . . 3-7 3.1 Correct Use of the Compressor ............ . 8-7 3.2 Incorrect Use .3-7 3.3 Compressed Air Treatment 3-7 3.4 Copyright 3-7 4 Transport...... 4-8 441 Transport Instructions .......6.20cscceeseeeeeeeee 4-8 4.2 Transport with a Fork Lift Truck or Lift Tuck «2... 4-8 43 Transport Using a Crane 4-9 4.4 Packaging 4-9 45 — Storage 4-9 5 Construction and Operation .. 5-10 5.1 Principle of Compression ..........00.cscceeseseeeees seve B= 10 5.2 Short Description... cceeceeeceseeseetseeseeeeetsees sete 5210 53 Compressor Control (Stop~Start Control) ..........eeeeeese eee rr0, 54 — Components of the Compressor Unit .........ceccevseeevsevstseeseete 5-11 6 Installation . 6-12 6.1 Installation Instructions 6-12 6.2 Fitting the Antivibration Mounts 6-12 6.3 Connection of the Compressed Air Supply . 6-13 64 Electrical Connection - 6-13Table of Contents 7 Putting into Operation . 10 7.1 Points to be Observed before Putting into Operation ceceeeeeeee 7-14 7.2 Direction of Rotation Check 7-14 7.3 Setting up the Overload Protection Trigger ..........sccsssseeseeeeteee 7-15 7.4 — Setting up the Pressure Switch ............. 7-16 7.4.1 Cut-in frequency of the compressor unit from "standstil” to "load" ......... 7= 17 Operation ........ ‘ -18 8.1 Starting and Stopping the Compressor Unit... -18 8.2 Faultfinding and Removal .... ; pe Gccoocd -18 8.2.1 Compressor does not start ....... : 8-18 8.2.2 Compressor starts with difficulty 8-18 8.2.3 Compressor overheating 6.0.0... ccececcseeeseteeceteereeeeeneeeee 8-19 8.2.4 The motor overload protection triggers after a short period .........+. 8-19 8.2.5 The motor overload protection triggers after a long period . 8.2.6 Compressor runs continuously, discharge pressure not reached 8.2.7 Compressor cutting in too often ........... 8.2.8 Compressor shuts down, ar escapes constantly atthe unloading valve. 8.2.9 Air escapes from the pressure switch 8.2.10 Whistling noises at the cylinder head 8.2.11 Safety valve blowing off prematurely 8.2.12 Oil consumption of compressor too high Maintenance .. 9.1 Observe the Following during all Maintenance and Repair Work: ........... 9-22 9.2 Regular Maintenance 2... 66. ceccesceseeeee @oGOTG00000 9-23 93 Checking the Oil Level and Topping Up (Compressor BIOCK) ............... 9-24 9.4 Air Receiver...... vote eee cerns 9-24 85 Oil Change (Compressor Block). 9-25 8.6 Cleaning or Changing the Air Fier .......00.c0ccseeecsee 26 9.7 Clean or Renew the Nonretutn Valve . 9-26 9.8 — Checking the Safety Valve 9-27 9.9 — Maintenance of the Motor Bearings .........2.ecseeeecseeee cesses 9= 28 9.10 Check o Renew the Cylinder Head and Valves (Compressor Block) - 9-28 9.11 Checking Compressor Unit Performance .............e.++ 9-29 ‘Spare Parts and After Sales Service .. 10-30 10.1 Service Parts and Expendable Parts . 10 - 30 10.2 Ordering Spare Parts 2.0... .ceceeceeeeeeseseeeeeneees 10 - 30 vee W381 11.1. Electrical Diagram 11-31 11.2 Maintenance Record 11-32Technical Specification 1 1.2 1.3 Technical Specification Compressor Unit Model ........ce. ciceeteetees KCD 125 - 100 Maximum gauge working pressure 0.0... .e.ececeee 10. bar Weight 88 kg Air receiver: Capacity .. 90 | Max. permissible gauge working pressure 11 bar Drawings: Dimensional drawing ...........00cceeecereee 1.9518.4 Electrical diagram ........... cesses. SKK.D-0496/00400 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 Quoted sound pressure level: Measurement to DIN 45635 (measurement of noise on machines, compressors) © 1 maistance © 1.6 mheight © Related point of measurement: from the directions of the cooling air exhaust and the cooling air inlet Highest sound pressure value with one block ............ 77 dB (A) Compressor Block Model Kc 125 secs je Block 125 Ymin Free alr delivered at 8 bar gauge working pressure . 82. min Maximum gauge working pressure 10. bar Number of cylinders... 20s cseceeeceecee eon Speed ... oacoeobsasesocxeAo8 ceeeses 14500 min=? Oll capacity oo... cece ceeeeeeerees je Block 0,13 1 Oll top-up quantity... cece je Block 0,05 | Theoretical inlet capacity ...........Technical Specification Eaten 1.4 15 1.6 17 Electrical Connection Mains voltage ...........+. eee eee eer tee G00) Phases ee 3/N/PE Frequency aD 50 Hz Max. mains fusing (slowblow or gl class) cee 1OA Power supply cable core cross—section ............. 4X4,5. mm? (CU multiple core cable) Maximum rated current In 21 A Drive Motor Rated power KW Rated speed min-1 Protection class .. ; Max. cut~in frequency .........csees Starting ....... : Air Main Pressure Switch Setting 5 fol ian 1 MDR 3/11 48 - - Possible adjustment range lr) of the air main pressure switch 36 ae ’ 1 fae T3/ i} 5 | 0123456789017 Cut-out pressure = bar Works settings of the pressure switch (compressor base load): Gauge cut-out pressure Pmax 9 bar Gauge cut—in pressure Prin... +--+ 7 bar Pressure difference Ap se bar Works settings of the pressure switch (compressor peak load): Gauge cut-out pressure Prax...» + 8 bar Gauge cut—in pressure Prin ......-. pooceooea yd Pressure difference Ap ves 2 bar Safety Valve Setting Opening pressure... ieieteeeeeteeeeteeeeeees TT barTechnical Specification 1.8 19 1.10 111 Installation Requirements Max. height above sea level at place of installation ...... 1000 m Min. ambient temperature 5 °C Max, ambient temperature .......ssceeeeseseeereerees 85°C Recommended minimum compressor space size (floor area x room height) ........eececeeevees 10M2X2,5 Mm Ventilation of installation spac Inlet ait Opening... se cceeeeeeeveseeeteeeees 0.4 me Exhaust air opening «2.0.0... secs cseeeseteeteeteens 04 me Recommended Oils Under normal operating conditions (see chapter 1.8), fill with engine oil of viscosity VG 10 to DIN 51 562. Recommended HD engine olfs to DIN 51 506 HD Ol; SAE 10; SAE 10/W30; SAE 10/W50 Air Receiver Charging Time ‘One compressor Air receiver charging time to 3 - 8 bar 7 min 40s ‘Two compressors Air receiver charging time to 3 ~ 8 bar 3 min 50s Dimensional Drawing (628 following page)001 — S21 Gow tts] ss. 001 - 0z1 Gow stveon| comer ReMescec ening yun Jossesdwog Zz = “Te Wu PEE a pe SLE “MIPIM IS8}Be15) 02 X08 @ wnow uoReIqA—nuy 4 i wtKAESER Safety ai 2 Safety Regulations Read this service manual carefully and observe cautionary references before putting this ‘compressor unit into operation and before carrying out any maintenance on the unit. 24 Explanation of Symbols and References A This symbol is placed before all regulations concerning safety where danger to life and limb can occur during work. It is especially import- ant that these regulations are observed and that extreme care Is taken. For their own protection, inform all other users of these safety regul: tions. Observe all general safety and acoldent 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 se- ‘quence of work so that damage and/or destruction of the compressor unit and/or other equipment is prevented. $3 This symbol identifies environmental care measure: - 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. 2.2 General Safety Precautions European Standards must be complied with when carrying out installation, operation, maintenance and repair of compressor units. Valid national regulations and standards must be complied with for those European Stan- dards that are not yet incorporated into national legislation. Users of compressor units located outside the jurisdiction of European Standards are ob- liged to comply with the valid safety and accident prevention regulations concerning the compressor unit in the country of use. H necessary, corresponding measures must be taken to ensure compliance with national regulations before the compressor is put into operation.Safety 2.3 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 compo- rents, ¢ 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 manu- facturer and the user. ¢ The oil change must be carried out according to the service manual, or at least once annually. Electrical Safety Attention! | The electrical system of a compressor unit must comply with the provi- slons of the European Standards EN 1012 — 1 and EN 60204 ~ 1) and, it necessary, with the local electricity supply authority regulations. Compressor units must be fitted with a main Isolating device, the oper- ation of which determines the start and end of the energy supply. Main isolating devices can be main switches or plug and socket con- nections 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 Iy (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.KAESER PRESSORS Safety 24 25 2.6 27 General References A 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 per- sonnel under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Before work is carried out on the electrical system, carry out the fol- lowing measures in the sequence shown. 1. Switch off all phases 2. Ensure the unit cannot be switched on again 3. Check that no voltage is present Discharge or shut off pipework under pressure if not stated otherwise in the service manual. Any alterations or reconstruction carried out without consultation with and without the previous consent of KAESER COMPRESSORS will in- validate the warranty. Spare Parts ‘Safe and reliable operation of the compressor unit is guaranteed only with KAESER original spare parts. Compressed Air Installation {a compressed air installation is enlarged or modified, check the blowotf pressure of the safety valves on the air receivers and in the pipework before a new compressor unit is in- stalled, I the blowoff pressure is too low, fit a safety valve with correspondingly higher blowoff Pressure or a second safety valve. Environmental Protection Condensate drainage & Condensate accumulating during compression must be drained via suitable draining system and collected in disposal canisters. The con- densate must be disposed of according to environmental regulations. Operational and repair materials, used parts & Dispose of all used materials and parts accumulating during oper- ation, maintenance and repair of the compressor unit according to environmental care regulations!General 3.1 32 3.3 3.4 General Attentior 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 liablty for any damage caused by such incorrect use; the user alone is iable for any risks incurred. Correct use of the compressor also encompasses compliance with the installation, re- moval, commissioning, operational and maintenance conditions laid down by the manufac- turer. Incorrect Use A Never direct compressed air toward persons. Compressed air is a con- centrated form of energy and as such Is dangerous to life. Compressed Air Treatment A 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. 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 per- sonnel 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 pur- pose of competition, or divuiged to any other third party.Transport 44 42 Transport 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. 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. Never drive directly underneath and lift. There is danger of tipping be- cause of the high point of gravity!KAESER Transport scans 43 44 45 Transport Using a Crane Attention! | _ If the compressor unit is transported by a crane the safety regulations concerning lifting appliances must be observed. A Do not stand underneath hanging loads. Do not exceed the max. permissible lifting weight of the lifting ap- pliance. Always use a sling when transporting the compressor unit with a crane. [Attention] Take care not to damage the condensate drain valve on the air recelver when fitting the sling. Packaging AA decisive factor in the type of packaging is the transport route. ‘The packaging conforms to packaging regulations laid down by the German Federal As- sociation 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). 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.5 5.1 5.2 5.3 Construction and Operation Construction and Operation items in () refer to components with iter number in the schematic diagram of the com- pressor unit (see chapter 5.4). Principle of Compression This reciprocating compressor is an air cooled, oil lubricated compressor using the prin- ciple of two 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 leaving the cylinder head enters the second cylinder head for boosting Via the interstage cooling pipe. Protection of the high pressure stage is ensured by a safety valve (9) placed between the first and second stage. The compressed air now enters the aftercooler (11). 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 cylinders are arranged as single cylinders in a V-configuration, The Deng of the motor shaft to the compressor block is fabricated as a crankshaft, A fan providing sufficient cooling for the motor and the compressor block is located at the N— end of the shaft. Heat is dissipated via the cooling fins on the cylinder and cylinder head. ‘The crankshaft is supported by roller bearings; the conrods are supported by a plain bear- ings and a roller bearing. The cylinder liner, piston, crankshaft and the conrod are auto- matically splash lubricated. ‘A-check valve (3) is fitted upstream of the air receiver (4) to prevent compressed air flowing back into the block ‘To provide an unloaded start a solenoid vaive (16) that is open when de—energised is fitted between the aftercooler pipe and the check valve (3). When the power supply is inter- rupted the solenoid valve (16) opens the venting line and the compressed air in the after- cooler pipe expands so that when the power supply returns an unloaded start of the com- pressor is ensured. The air receiver (4) is constructed to the provisions of the pressure vessels act and fitted with all necessary fittings such as safety valve (5), pressure gauge (8), pressure switch (6) and nonretum valve (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, de- ending on the air demand, between the two operating states "load" and “standstill” within the limits: Prin / Pmax 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. 5-10NUS] Construction and Operation COMPRESSORS 5.4 Components of the Compressor Unit 2 @ 4 8 6 ot 5 m2 87 14 1 Air iter 8 Pressure gauge cleans indicates the current pressure the inlet air in the air receiver 2 Compressor block 9 Oil level sight glass raws in the air and compresses it to the discharge pressure 3 Nonreturn valve 10 Oil filer with crankcase venting prevents the compressed air from plug flowing back into the block 4 Air receiver 11° Olldrain plug compressed air tank and accumulation of condensate 5 Safety valve 12 Compressed air discharge connection protects the air receiver, blows off to the alr mains i the max. working pressure is exceeded 6 Pressure switch 13 Condensate drain cock controls compressor stop and start 7 Electric motor 14 Direction arrow on the fan guard drives the compressor block; Fan on N shaft end provides the necessary cooling air6.1 62 Installation Installation 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 iniet 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 re- mains within the limits stated in chapter 1.8. Shut down the compressor.Putting into Operation TA A Break the power supply by operating and locking out the main isolat ing device (main switch or mains plug) to prevent an accidental com- pressor start. «= Loosen the screws (5) to the right and left of the cover (1). q Remove the cover (1) of the pressure switch 1 Tum the dial (2) with a screwdriver so that the mark (¥y) coincides with the value of the rated motor current on the dial (2), A Replace the cover (1) after every adjustment of the pressure switch and before starting the compressor unit. 1 Replace the cover (1) Setting up the Pressure Switch A Break the power supply by operating and locking out the main isolat- ing 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). 1 Cover 2 Screw 3. "Upper switching point” (Cutout pressure) adjusting screw 4. Pressure difference adjusting screw 5 ONJOFF ~ Switch (OFF/AUTO) «= Shut down the compressor unit (see chapter 8.1) A Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start,Putting into Operation 744 cx Unscrew the screws (2) to the right and left of the cover (1). «7 Remove the cover (1) of the pressure switch. or Carry out the adjustment of the pressure switch. A Replace the cover (1) after every adjustment of the pressure switch and before starting the compressor unit. ex Replace the cover (1). To increase the cut-out pressure: ex Tum the screw (8) clockwise in the "+"direction. To decrease the cut-out pressure: 17 Tum the screw (3) counterclockwise in the "-" direction. To increase the pressure difference between the cut—in and cut-out pressures: «7 Turn the screw (4) clockwise in the "+" direction, To decrease the pressure difference between the cut dlrectc and cut-out pressures: i Tum the screw (4) counterclockwise 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 timited range by changing the switching difference. To change the cut—in fre- quency the pressure switch must be adjusted (see chapter 7.4). Attention! | See chapter 1.5 for the maximum cut—in frequency from "standstil “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 frequency.a4 82 824 82.2 Operation Operation Starting and Stopping the Compressor Unit Starting the compressor unit 1 Operate the main isolating device (main switch or plug, see chapter 2.3). 1 ON/OFF switch “0” position = OFF "position = AUTO © Switch on the compressor unit at the pressure switch (turn switch to position “!"). ‘Shutting down the compressor unit © Switch off the compressor unit at the pressure switch (turn switch to position “O"). © Operate and lock out the main isolating device to isolate the compressor from the mains power supply. Faultfinding and Removal A General safety regulations (see chapter 2) and local safety regulations must be complied with during faultfinding and removal procedures. Starting after a detect: ‘See chapter 7 ‘Putting into Operation’. Explanation of symbols for the following fault diagnosis: 2k 1 — have checked by a specialist. 2k 2 ~ contact KAESER customer service department. Compressor does not start Possible cause: No motor power supply, fuses blown, Replace the fuses; > 1 Contact in pressure switch defective. Renew the pressure switch; :k 1 Motor overload protection triggered. Check the setting (see chapter 7.9); :k 1 Compressor starts with difficulty Possible cause: Damaged bearings. Renew the bearings or fit an exchange compressor; > 2. 8-18Operation 82.3 82.4 825 8.2.6 Pistons siezed {no oll or wrong oil). Power supply fault (2—phase running). Oil level too high. Compressor overheating Possible cau: ‘Ambient temperature too high (over 40 °C). Wrong direction of rotation (observe the direction arrow), The fan cannot draw in air freely. Valve plate leaking, coked or the valve reeds are broken. 22, Check the power supply (fuses); 2k 1. Reduce the oil level to the maximum mark on the oil level sight glass (see chapter 9.3) Remedy: Lower the ambient temperature (see chap- ter 1.8). Change over L1 and L2 terminals (see chapter 7.2); >k 1. Ensure that inlet air is available for the fan. Check, decoke or renew valve plate; > 1 and > 2. The motor overload protection triggers after a short period Possible cause: Power supply fault (2~phase running). Defective motor. Remedy: Check the power supply (fuses); > 1 Change the motor; * 1 und 2k 2 ‘The motor overload protection triggers after a long period Possible cause: Setting too low. Current too high because of low supply voltage. Remedy: Check the setting (see chapter 7.3); > 1. Check the cross—section of power supply cable (see chapter 6.4); >k 1 Check the power supply terminals; tighten the screws. Compressor runs continuously, discharge pressure not reached Possible cause: Air fitter clogged. Valve plate leaking, coked or valve reeds broken, Pressure losses within the unit. Air demand higher than the capacity of the compressor. Losses at the consumer / in the air main, Remedy: Clean or renew the air filter (see chapter 9.6); > 1 Check, decoke or renew valve plate; > 1 and > 2, Brush soapy water on piping and fittings, seal leaks, renew leaking parts; > 1. Extend the compressed air supply. Cheok for possible leakage points.Operation 82.7 32.9 8.2.10 8.2.11 8.2.12 Compressor cutting in too often Possible cause: Air receiver filled with condensate up to the discharge cock, Remedy: Drain the condensate (observe environmen- tal care regulations), carry out routine main- tenance regularly (See chapter 9.4); 2k 1. Compressor shuts down, air escapes constantly at the unloading valve Possible cause: Defective nonreturn valve. Al escapes from the pressure switch Possible caus Defective diaphragm. Whistling noises at the cylinder head Possible cause: Loose cylinder head bolts or defective gas- kets. Safety valve blowing off prematurely Possible cause: Safety valve blows, even though the cut— ‘out pressure is not yet reached. Defective valve spring. Maladjusted. ‘Safety valve was opened, dirt particles stuck in valve seat. ll consumption of compressor too high Possible cause: Viscosity of oil too low. Defective crankcase venting plug. Remedy: Renew the seal or renew the valve cone (see chapter 9.7); > 1. Remedy: Renew the pressure switch; > 1 Remedy: Tighten the bolts or renew the gaskets; > 1 and > 2. Remedy: Check that the pressure gauge functions Correctly, replace if necessary. Check the pressure setting, Renew the safety valve; 2 1. Setting 1 bar above max. gauge working pressure (see chapter 1.1) of the compres- sor unit 1 Open the safety valve completely for a short Period to allow it to blow itself clean. Remedy: Fill with correct oil (see chapter 1.9); > 1. Clean or renew the crankcase venting plug; ot.Operation Exaeera Piston rings worn or damaged. Renew piston rings and cylinder; >k 2. Piston rings worn or damaged after only a Renew piston rings and oylinder; +k 2. short period. (ensure that the inlet air is clean, e.g. by using an air fitter with a higher grade of fil- tration).KAESER Maintenance rao 9 Maintenance 9.1 Observe the Following during all Maintenance and Repair Work: Attention! Attention! sy 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 per- sonnel under the supervision and guidance of a skilled electrician and In accordance with electrical engineering rules and regulations. Before any maintenance work Is carried out on the compressor unit break the power supply by operating and locking out the main isolat- ing device (mains supply switch or mains plug, see chapter 2.3) to prevent an accidental compressor start. It work is to be done on the pressurised pipework of the compressor unit the pipework must be vented beforehand (vent the air receiver), Before starting the compressor again ensure that no maintenance per- sonnel are working on the compressor unit and that all covers are fitted. To start the compressor unit (see chapter 8.1). ‘Always check and tighten all screwed fittings that were removed or loosened during maintenance and repair work. Dispose of all used materials and parts accumulating during oper- ation, maintenance and repair of the compressor unit according to environmental care regulations!OS a] Maintenance ha 9.2 Regular Maintenance Period Work to be done ‘See chapter ‘daily ‘check the oil level in the compressor block 93 drain the condensate from the air receiver 9.4 50 hours after first put- | check all electrical screw connections for tight- [7.1 ting into operation Ness and tighten if necessary carry out a compressor oll change os 500 hours or at least carry out a compressor oil change * 9.5, aes check and clean the air filter * 9.6 [check and clean the nonretum valve * a7 check the safety valve 98 3000 hours check the cylinder head and valves for correct |9.10 function 10000 hours: renew the motor bearings 9.9 carry out a general overhaul ofthe compressor _[@.10 * The maintenance interval can vary according to model, installation, cut—in frequency and the ambient conditions. We recommend that a record is kept of all maintenance work ‘A sample maintenance record is provided in chapter 11.2Maintenance 9.3 Checking the Oil Level and Topping Up (Compressor Block) CCheck the cil level atthe oll evel sight glass daily and before each star. Attention! | _ If the oil level has sunk to the lower mark, top up the oll immediately — according to the oll recommendations (see chapter 1.9). Never top up to a level exceeding the maximum oll mark on the oll level sight glass. Attention! | When topping up the oil always use a strainer or pour the oll directly from the new oll can, max. min. 1 Oil filer with crankcase venting plug 2 Oil level sight glass 1 Shut down the compressor (see chapter 8.1). A Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start. Ex Remove the crankcase venting plug (1) from the oil filer. Attention! | As the oll must flow through the crankcase first, the maximum oil level Is reached after a few minutes have elapsed. ex Fillwith oil until the maximum oil level mark is reached. See chapter 1.3 for the quan- tity of oll required for topping up from the minimum mark to the maximum mark. «7 Replace the crankcase venting plug in the oi filler 94 Air Receiver Attention! | According to current legislation for pressure vessels, checks must be "carried out within defined time periods. The regulations of the country concerned must be observed. Drain the condensate collecting in the air receiver daily through the condensate drain cock (1) 9-24KAESER 95 Maintenance acacia 3 Drain the condensate into a suitable container and dispose of accord- Ing to environmental care regulations! 1 Condensate drain cock Oil Change (Compressor Block) Change the oil with the compressor unit at normal operating temperature A Danger of scalding by hot oil Danger of burns from hot components Change the oil after the first 50 service hours approximately. Change the oil after every further 500 service hours or at least annually. ¥f, under unsuitable operating conditions, condensed water is observed in the oll, recognis- able by the milky colour in the oil level sight glass (2), carry out an oil change immediately. See chapter 1.9 for suitable oils 1 Oil filler 2 Oil level sight glass 3. Oil drain plug = Shut down the compressor (see chapter 8.1) AN Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start sx Remove the crankcase venting plug (1) from the oll filler. 1 Prepare a container to catch the oll96 97 Maintenance BS 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 r= Screw the oil drain plug back into the crankcase. At ion! |_ When topping up the oil always use a strainer or pour the oil directly from the new oll can. = Fill up with new oil (see chapter 9.3) Cleaning or Changing the Air Filter The replaceable cartridge (2) is made of foam. Ian obvious layer of dust is found on the fier cartridges, they must be cleaned. The fiter inserts should be cleaned at the latest after 500 service hours. 1 Airfilter cap 2 Filter insert 3. Silencer «= Shut down the compressor (see chapter 8.1) A Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start, 1 Remove the rubber cap of the alr filter (1) 1 Take out the fiter cartridge, wash it in hot water with a grease solvent additive and then carefully rinse. 1 Clean out the filter housing. Clean the sealing surfaces very carefully. Attentio Ifthe inserts are heavily contaminated or have been cleaned several times they should be changed. ur After drying the filter cartridge insert it again. w= Fit the rubber cap of the air filter (1) again. Clean or Renew the Nonreturn Valve ‘The nonretum valve is fitted to the inlet port of the compressed air line on the air receiver. It prevents the compressed ait flowing back from the air receiver into the compressor block.De Uta] Maintenance corer Galatea) 98 Check and, if necessary, clean the nonreturn valve every 500 service hours. 4 j 2 1 1 Nonretum valve 4 Valve seat 2 End plug 5 Spring 3. Valve cone 6 Sealing ring = Shut down the compressor (see chapter 8.1). A Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start. «7 [Isolate the compressor unit from the air main (close the user's shut-off valve) ex Vent the air receiver with the condensate drain cock (see chapter 9.4). A Do not open the end plug in the valve housing until the pressure gauge indicates zero. ex Unscrew the end plug (2) in the valve housing, s7 Clean the valve cone (3) and valve seat (4). 1 Renew the valve cone (8), the spring (6) and the sealing ring (6) if they are heavily worn or damaged. t= Reassemble in the reverse order. Checking the Safety Valve Ifthe maximum permissible gauge working pressure in the air receiver is exceeded, the safety vaive (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 Knurled ring 2 Safety valveMaintenance 9.9 9.10 Attention!] Always wear ear muffs during the safety valve check because of the very loud noise occurring when the valve is opened. 17 Shut down the compressor unit under pressurisation (see chapter 8.1) A Break the power supply by operating and locking out the main isolat- ing device (main switch or mains plug) to prevent an accidental com- pressor start. cx Turn the knurled ring (1) on the safety valve (2) anticlockwise until air blows off. ‘Attention! | A detective safety valve must be renewed complete. Attention! | Adjustment of the safety valve setting and removal of the seal is for- [Attentiont | bidden and invalidates 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! | The bearings must be changed by KAESER—Service when the above ‘1 maintenance is due. 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.Maintenance Gaal 9.11 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) A Break the power supply by operating and locking out the main isolat- Ing device (main switch or mains plug) to prevent an accidental com- pressor 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 vaive on the air receiver, o7 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 specifi cation (see chapter 1.10). Q qSpare Parts and After Sales Service 10 10.1 10.2 Spare Parts and After Sales Service Service Parts and Expendable Parts Nonreturn valve 2off 4.2400.2 Lubricating oil 1 litres 9.0892.0 Pg (AESER KOMPRESSOREN GmbH ] -- rc Ordering Spare Parts When ordering spare parts always state (see nameplate): = Compressor mode! — Year of manufacture = Part number = Serial number Important for all queries ux 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 iting 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 - 30LNs] Appendix eer i 1 Appendix 11.1. Electrical Diagram (see following page) 1-31a Tee ana = es Z wun-sossa.duos 6 a a A 43aS3V> aaa os Hl ejou aeeastuo Joeu aang woyenynads eupay ‘eruew ena 985. woypame JUDD UayEUDad FERUDEL “ReueN BARE OS "Tq BIqe> 404>8UU0) finyg pue ajge> soyzauue) yim se fa panies asng I z zAppendix 11.2 Maintenance Record Serial number: ........--+.++ Date I Description of work. Operating hours Signature 11-32