Assembly and operating manual

Transcription

1 Manufacturer: KAESER KOMPRESSOREN GmbH Coburg PO Box 2143 GERMANY Tel. +49-(0) Fax +49-(0)

2 Original instructions /KKW/PEPC 1.04 en SBA-KOLBEN-AGGREGAT 1-STUFIG

3 Contents 1 Regarding this document 1.1 Using this document Further documents Copyright Symbols and markings Warning notices Other notices and symbols Technical Specification 2.1 Nameplate Options Weight Compressor Block Ambient Conditions Ventilation Pressure Sound Pressure Level Motor power and speed Compressor oil recommendations Compressor oil charge Power Supply Three-phase power supply Power supply specifications Electrical connection details for oil level monitoring Network Conditions Mains conditions at 400V/3/50Hz Machine duty cycle Safety and Responsibility 3.1 Basic Information Specified Use Improper use User's responsibilities Observe statutory and universally accepted regulations Defining personnel Inspection Schedules and Accident Prevention Regulations Dangers Safely dealing with sources of danger Safe machine operation Organisational Measures Danger Areas Safety Devices Safety Signs Information signs Emergency situations Correct fire fighting Remove any compressor oil from your person Warranty Environmental Protection Design and Function 4.1 Outline of the machine Main components Function Options Oil level monitoring i

4 Contents Adjustable machine mountings Silenced air filter Air filter with plastic casing Castors Bolt-on machine mounts for mounting on tank Operating modes and control modes Operating modes External control unit Safety devices Safety and regulating devices Accessories Installation and Operating Conditions 5.1 Safety Installation conditions Determining location and clearances Ensuring adequate ventilation Operation in a compressed air network Installation 6.1 Safety Reporting Transport Damage Fitting the antivibration mounts Compressed Air Connection Typical installation for safety and regulating devices Connecting the Power Supply Options Oil level monitoring Anchoring the Machine Mounting the machine on a compressed air tank Retrofitting the Sound Enclosure (accessory) Dismantling the sound enclosure Vent the machine (depressurize) Fitting the Sound Enclosure Initial Start-up 7.1 Safety Instructions to be observed before commissioning or recommissioning Checking installation and operating conditions Motor overload protection Checking the motor protection device Checking direction of rotation Starting the Machine for the First Time Measuring the air receiver filling time Operation 8.1 Switching on and off Direct online starting Direct online start with solenoid valve Star-delta starting Fault Recognition and Rectification 9.1 Basic Information Alarms Maintenance 10.1 Safety ii

5 Contents 10.2 Maintenance Schedule Logging maintenance work Regular maintenance tasks Oil change interval Regular service tasks Maintaining the air cooler or fan guard Cleaning the air cooler or fan guard Air filter maintenance Air filter (noise absorbing) maintenance Air filter (with plastic casing) Drive Motor Maintenance Checking the oil level Topping up the compressor oil Changing the compressor oil Testing the pressure relief valve Pressure relief valves on the cylinder head, collecting pipe and air cooler Venting the machine (de-pressurising) Solenoid Valve Maintenance Clean the solenoid valve Changing the solenoid valve Cylinder head and valves Checking the cylinder head and valves Cleaning the cylinder head and valves Starting the machine and carrying out a trial run Document maintenance and service work Spares, Operating Materials, Service 11.1 Note the Nameplate Ordering consumable parts and operating fluids/materials KAESER AIR SERVICE Service Addresses Spare Parts for Service and Repair Decommissioning, Storage and Transport 12.1 De-commissioning Packing Storage Transporting Safety Transporting with a forklift truck Transporting with a crane Disposal Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Dimensional Drawing Electrical diagram iii

6 Contents iv

7 List of Illustrations Fig. 1 Location of safety signs Fig. 2 List of main components Fig. 3 Machine layout Fig. 4 Oil level monitoring Fig. 5 Adjustable machine mountings Fig. 6 Silenced air filter Fig. 7 Air filter with plastic casing Fig. 8 Castors Fig. 9 Bolt-on machine foot Fig. 10 Recommended machine placement and dimensions [mm] Fig. 11 Fitting the antivibration mounts Fig. 12 Compressed air connection Fig. 13 Suggested Safety and Control Devices Fig. 14 Oil level monitor connections Fig. 15 Changing the oil level monitoring setting Fig. 16 Securing the bolt-on machine mounts Fig. 17 Securing the bolt-on machine mounts Fig. 18 Removing the air filter Fig. 19 Fitting the Sound Enclosure Fig. 20 Switching on and off Fig. 21 Cleaning the air cooler or fan guard Fig. 22 Air filter maintenance Fig. 23 Air Filter (noise absorbing) Maintenance Fig. 24 Air filter (with plastic casing) Fig. 25 Checking the oil level Fig. 26 Changing the compressor oil Fig. 27 Checking the pressure relief valves on the cylinder head, collecting pipe and air cooler Fig. 28 Cleaning the solenoid valve Fig. 29 Changing the solenoid valve Fig. 30 Consumable parts Fig. 31 Transporting with a forklift truck Fig. 32 Transporting with a crane v

8 List of Illustrations vi

9 List of Tables Tab. 1 The levels of danger and their meaning... 2 Tab. 2 Nameplate... 3 Tab. 3 Options... 3 Tab. 4 Weight... 3 Tab. 5 Compressor block specification... 4 Tab. 6 Ambient Conditions... 4 Tab. 7 Ventilation... 4 Tab. 8 Pressure relief valve activating pressure EPC Tab. 9 Pressure relief valve activating pressure EPC 630 bis EPC Tab. 10 Sound Pressure Level... 5 Tab. 11 Power and speed... 6 Tab. 12 Permissible starting frequency... 6 Tab. 13 Compressor oil recommendations... 6 Tab. 14 Compressor oil charge... 7 Tab. 15 Supply details 230V/3/50Hz... 8 Tab. 16 Supply details 400V/3/50Hz... 9 Tab. 17 Supply details 500V/3/50Hz... 9 Tab. 18 Supply details 690V/3/50Hz... 9 Tab. 19 Supply details 230V/3/60Hz Tab. 20 Supply details 380V/3/60Hz Tab. 21 Supply details 440V/3/60Hz Tab. 22 Supply details 460V/3/60Hz Tab. 23 Connection details for oil level monitoring Tab. 24 Network impedance Tab. 25 Machine duty cycle Tab. 26 Inspection intervals according to Ordinance on Industrial Safety and Health Tab. 27 Danger Areas Tab. 28 Safety Signs Tab. 29 Information signs Tab. 30 Oil level monitor Tab. 31 Re-commissioning after storage Tab. 32 Checklist of installation conditions Tab. 33 Air receiver charging time Tab. 34 Faults and remedies Tab. 35 Regular maintenance tasks Tab. 36 Oil change intervals Tab. 37 Regular service tasks Tab. 38 Screw tightening torques Tab. 39 Logged maintenance tasks Tab. 40 Consumable parts vii

10 List of Tables viii

11 1 Regarding this document 1.1 Using this document 1 Regarding this document 1.1 Using this document This document, hereafter called the service manual, contains important information about all life phases of the machine. The service manual is part of the machine. It describes the machine as it was at the time of first delivery after manufacture. Keep the service manual in a safe place throughout the life of the machine. Pass the manual on to the next owner/user of the machine. Ensure that all amendments received are entered in the manual. Enter details from the machine nameplate and individual items of equipment in the table in chapter Further documents Included with this operating manual are additional documents intended to assist in the safe operation of the machine: Installation declaration according to applicable directives. Missing documents can be requested from KAESER. Make sure all documents are complete and observe the instructions contained in them. Make sure you provide the data from the nameplate when ordering documents. 1.3 Copyright This service manual is copyright protected. Queries regarding use or duplication of the documentation should be referred to KAESER. Correct use of information will be fully supported. 1.4 Symbols and markings Warning notices Warning notices indicate three levels of danger signified by the signal word. DANGER WARNING CAUTION DANGER These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. The signal word "DANGER" indicates that death or severe injury can result from ignoring the warning. The measures required to protect yourself from danger are shown here. 1

12 1 Regarding this document 1.4 Symbols and markings Always read and comply with warning instructions. Signal word Meaning DANGER Consequences of non-observance Warns of an imminent threat of danger Death or serious injury may result WARNING Warns of possible danger Death or serious injury are possible CAUTION Warns of a possibly dangerous situation Light injuries or material damage are possible Tab. 1 The levels of danger and their meaning Other notices and symbols This symbol refers to particularly important information. Material Precondition Here you will find details on special tools, operating materials or spare parts. Here you will find conditional requirements necessary to carry out the task. Here conditions relevant to safety are named that will help you to avoid dangerous situations. Option H1 This symbol is is placed by lists of actions comprising one stage of a task.in lists of actions with several stages the sequence of actions is numbered. This symbol is is placed by lists of actions comprising one stage of a task. In lists of actions with several stages the sequence of actions is numbered.information that refers to only one option is marked with an indicator (e.g.: H1 means that this section is only valid for machines with adjustable machine feet). Information referring to potential problems are identified by a question mark. The cause is named in the help text and a remedy given. This symbol refers to important information or measures concerning environmental protection. Further information Here, your attention is drawn to further topics. 2

13 2 Technical Specification 2.1 Nameplate 2 Technical Specification 2.1 Nameplate The machine's nameplate provides the model designation and important technical information. Enter here the nameplate data as a reference: Feature Reciprocating Compressor Part No. Serial No. Year of manufacture Maximum working pressure Delivery Rated voltage Synchronous speed Rated power Ambient temperature Value Tab. 2 Nameplate 2.2 Options The table contains a list of possible options. Enter options here as a reference. Option Option code Available? Oil level monitor C5 Adjustable machine mountings H1 Silenced air filter H9 Air filter with plastic casing H10 Castors H14 Bolt-on machine mounts for mounting on tank H20 Tab. 3 Options 2.3 Weight The weight indicated is the maximum weight. The actual weight depends on equipment fitted. Model Weight [kg] EPC 340-G 40/95* EPC 440-G 50/100* * Machine with sound enclosure 3

14 2 Technical Specification 2.4 Compressor Block Model Weight [kg] EPC 630-G 70/130* EPC 840-G 70/130* EPC 1100-G 100/240* EPC 1500-G 130/260* * Machine with sound enclosure Tab. 4 Weight 2.4 Compressor Block Model Theoretical displacement [l/min] Delivery at 6 bar [l/min] Number of cylinders KC KC KC KC KC KC Tab. 5 Compressor block specification 2.5 Ambient Conditions Installation Maximum altitude AMSL* [m] Permissible ambient temperature [ C] * Higher altitudes are permissible only after consultation with the manufacturer. Tab. 6 Ambient Conditions 2.6 Ventilation The values given are minimum guide values. Model Inlet aperture (Z) [m 2 ] Exhaust fan (A) [m 3 /h] EPC 340-G EPC 440-G EPC 630-G EPC 840-G EPC 1100-G *Forced ventilation: required airflow for static ventilator thrust at maximum duty cycle [ΔT 10 K] 4

15 2 Technical Specification 2.7 Pressure Model Inlet aperture (Z) [m 2 ] Exhaust fan (A) [m 3 /h] EPC 1500-G *Forced ventilation: required airflow for static ventilator thrust at maximum duty cycle [ΔT 10 K] Tab. 7 Ventilation 2.7 Pressure Activating pressure of the cylinder relief valve EPC 340 Maximum working overpressure [bar] Activating pressure [bar] 14 Tab. 8 Pressure relief valve activating pressure EPC Activating pressure of the collecting pipe relief valve EPC 630 bis EPC 1500 Maximum working overpressure [bar] Activating pressure [bar] 12.5 Tab. 9 Pressure relief valve activating pressure EPC 630 bis EPC Sound Pressure Level Operational state Operating mode LOAD at rated speed, rated air flow and nominal pressure. Measurement conditions Mean sound pressure level at 1 m distance to EN ISO 2151 Model Sound pressure level [db(a)] Sound pressure level with enclosure [db(a)] EPC 340-G EPC 440-G EPC 630-G EPC 840-G EPC 1100-G EPC 1500-G Tab. 10 Sound Pressure Level 5

16 2 Technical Specification 2.9 Motor power and speed 2.9 Motor power and speed Read off the enclosure protection rating from the motor nameplate and enter in the table: Model Rated power [kw] Synchronous speed [min -1 ] (50 Hz) Synchronous speed [min -1 ] (60 Hz) KC KC KC KC KC KC Degree of protection Tab. 11 Power and speed Permissible starting frequency Read-off the permissible starting frequency of the motor from the table below. Rated power [kw] Permissible starting frequency [1/h] Tab. 12 Permissible starting frequency 2.10 Compressor oil recommendations The standard compressor oil is SAE 5 W30 or VDL 150. For special applications FGPor S 150 compressor oil is used and the machine carries a sticker indicating this. Information on ordering compressor oil is found in chapter 11. Mark the oil that your compressor contains in the table below. Standard oil EPC 340/EPC 440 EPC 630 bis EPC 1500 Special oil Oil type SAE 5 W30 VDL 150 FGP S 150 * Cool to moderate ambient temperatures, low humidity, low to average duty cycle. 6

17 2 Technical Specification 2.11 Power Supply Application Maximum permissible oil change interval in operating hours/years. Oil contained in my compressor Standard oil EPC 340/EPC 440 EPC 630 bis EPC 1500 Standard oil for all applications except in connection with foodstuffs. Standard oil for all applications except in connection with foodstuffs. Special oil Specifically for machines in applications where the compressed air may come into contact with foodstuff. 1000/2* 1000/1* 1000/2* 2000/1* * Cool to moderate ambient temperatures, low humidity, low to average duty cycle. Special oil for machines under high operational demand. Tab. 13 Compressor oil recommendations Compressor oil charge Model Total charge [litres] Topping up volume [litres] (minimum maximum) KC KC KC KC KC KC Tab. 14 Compressor oil charge 2.11 Power Supply Basic requirements The machine is designed for a power supply conforming to EN (IEC ), section 4.3. In the absence of other user-specified conditions, the limits laid down in this standard must be adhered to. It is recommended that the supplier and user confer and agree on the basis of the EN , Annex B Three-phase power supply The machine requires a symmetrical three-phase power supply. In a symmetrical three-phase supply the phase angles and voltages are all the same. 7

18 2 Technical Specification 2.11 Power Supply This machine may only be supplied from an earthed TN or TT three-phase supply in which the neutral point is earthed. Connection to an IT supply is not permitted without taking further measures (earth leak detection, etc.). Further information When connecting to a European 400 V/3/50 Hz power supply the requirements in chapter 2.12 are also to be observed. See electrical diagram in Power supply specifications The following supply cable conductor cross sections (copper multi-core) and fusing (slow-blow class gl) are selected according to German DIN VDE (IEC and IEC )) and DIN VDE standards for 30 C ambient temperature and wiring type C. For other application conditions, check conductor diameters and change accordingly. Cables laid side-by-side must be separated by a distance equal to one cable diameter. Other conditions would include, for example: Higher temperature Other cable installation method Cable length >50 m Bundled cables Mains frequency: 50 Hz Rated voltage: 230V±10%/3/50Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x x G x x G x x G x x G x x G x x 6 Pressure switch Controller (star-delta) Tab. 15 Supply details 230V/3/50Hz 8

19 2 Technical Specification 2.11 Power Supply Rated voltage: 400V±10%/3/50Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x x G x x G x x G x x G x x G x x 2.5 Pressure switch Controller (star-delta) Tab. 16 Supply details 400V/3/50Hz Rated voltage: 500V±10%/3/50Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x x G x x G x x G x x G x x G x x 2.5 Pressure switch Controller (star-delta) Tab. 17 Supply details 500V/3/50Hz Rated voltage: 690V±10%/3/50Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x G x G x G x G x 2.5 Pressure switch Controller (star-delta) 9

20 2 Technical Specification 2.11 Power Supply EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 1500-G x 2.5 Pressure switch Controller (star-delta) Tab. 18 Supply details 690V/3/50Hz Mains frequency: 60 Hz Rated voltage: 230V±10%/3/60Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x G x G x x G x x G x x G x x 6 Pressure switch Controller (star-delta) Tab. 19 Supply details 230V/3/60Hz Rated voltage: 380V±10%/3/60Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x G x G x x G x x G x x G x x 2.5 Pressure switch Controller (star-delta) Tab. 20 Supply details 380V/3/60Hz 10

21 2 Technical Specification 2.11 Power Supply Rated voltage: 440V±10%/3/60Hz EPC type Current input [A] Direct online starting Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x G x G x x G x x G x x G x x 2.5 Pressure switch Controller (star-delta) Tab. 21 Supply details 440V/3/60Hz Rated voltage: 460V±10%/3/60Hz EPC type Current input [A] Direct online start Backup fuse [A] Supply cable [mm 2 ] Star-delta starting Backup fuse [A] Supply cable [mm 2 ] 340-G x G x G x x G x x G x x G x x 2.5 Pressure switch Controller (star-delta) Tab. 22 Supply details 460V/3/60Hz Option C5 Electrical connection details for oil level monitoring Characteristic Contact load capacity Value max. 1 A max. 230 V AC / 48 V DC max. 26 VA / 20 W Maximum medium temperature 110 C Maximum ambient temperature 110 C Enclosure protection IP 65 Tab. 23 Connection details for oil level monitoring 11

22 2 Technical Specification 2.12 Network Conditions 2.12 Network Conditions The machines listed in table are intended for operation with a public power supply with a network impedance at the transfer point (house connection) of maximum Z max [Ohm]. The operator must ensure that the machines are only connected to a supply network that meets these requirements. The local electricity utility will provide information on the network impedance Mains conditions at 400V/3/50Hz Model Start configuration Starts [1/h] Z max [Ω] EPC 340 Direct online Star-delta EPC 440 Direct online Star-delta EPC 630 Direct online Star-delta EPC 840 Direct online Star-delta EPC 1100 Direct online Star-delta EPC 1500 Direct online Star-delta Tab. 24 Network impedance 2.13 Machine duty cycle Calculating the cycling period: Calculating the duty cycle: Example The following values are valid for: 20 C ambient temperature 30 % relative humidity 1013 mbar air pressure Cycling time = time under load + time at standstill time under load Duty cycle [%] = time under load + standstill time x minutes x 100 % = 60 % 20 minutes Model Permissible duty cycle 2 [%] Cycling period 1 [min] EPC 340-G

23 2 Technical Specification 2.13 Machine duty cycle Model Permissible duty cycle 2 [%] Cycling period 1 [min] EPC 440-G EPC 630-G EPC 840-G EPC 1100-G EPC 1500-G Tab. 25 Machine duty cycle 13

24 3 Safety and Responsibility 3.1 Basic Information 3 Safety and Responsibility 3.1 Basic Information The machine is manufactured to the latest engineering standards and acknowledged safety regulations. Nevertheless, dangers can arise through its operation: danger to life and limb of the operator or third parties, impairments to the machine and other material assets. DANGER Disregard of these instructions can result in serious injury. Read the service manual carefully and take notice of the contents for safe machine operation. Use this machine only if it is in a technically perfect condition and only for the purpose for which it is intended; observe all safety measures and the instructions in the service manual. Immediately rectify (have rectified) any faults that could be detrimental to safety. 3.2 Specified Use The machine is intended solely for generating compressed air for industrial use. Any other use is considered incorrect. The manufacturer is not liable for any damages that may result therefrom. The user alone is liable for any risks incurred. Keep to the specifications listed in this service manual. Operate the machine only within its performance limits and under the permitted ambient conditions. Do not use compressed air for breathing purposes unless it is specifically treated. Do not use compressed for any application that will bring it into direct contact with foodstuffs unless it is specifically treated. 3.3 Improper use Never direct compressed air at persons or animals. Use hot cooling air for heating purposes only if there is no risk to the health of humans or animals. If necessary, hot cooling air should be treated by suitable means. Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours. Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force. As covered by the area of application of directive 2000/14/EC, the machine is not intended for use in the open air. 3.4 User's responsibilities Observe statutory and universally accepted regulations These are, for example, nationally applied European directives and/or valid national legislation, safety and accident prevention regulations. 14

25 3 Safety and Responsibility 3.4 User's responsibilities Observe relevant statutory and accepted regulations during installation, operation and maintenance of the machine Defining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the possible dangers involved. Authorised operators possess the following qualifications: are of legal age, are conversant with and adhere to the safety instructions and sections of the service manual relevant to operation, have received adequate training and authorisation to operate electrical and compressed air devices. Authorized installation and maintenance personnel have the following qualifications: are of legal age, have read, are conversant with and adhere to the safety instructions and sections of the service manual applicable to installation and maintenance, are fully conversant with the safety concepts and regulations of electrical and compressed air engineering, are able to recognise the possible dangers of electrical and compressed air devices and take appropriate measures to safeguard persons and property, they have received adequate training in and authorization for the safe installation and maintenance of this machine. Ensure that personnel entrusted with operation, installation and maintenance are qualified and authorized to carry out their tasks Inspection Schedules and Accident Prevention Regulations The machine is subject to local inspection schedules. Examples of German inspection schedules Recurring inspections to BGR 500, chapter 2.11: The user must ensure that from a rated motor power greater than 0.5 kw the machine's safety devices are checked for function at least once annually. Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health with maximum intervals as laid down in Para. 15. Inspection Inspection interval Inspecting authority Installation and equipment inspection Internal inspection Strength test Before commissioning every 5 years after installation or the last inspection, every 10 years after installation or the last inspection, Competent persons (e.g. KAESER Service Technician) Competent persons (e.g. KAESER Service Technician) Competent persons (e.g. KAESER Service Technician) Tab. 26 Inspection intervals according to Ordinance on Industrial Safety and Health 15

26 3 Safety and Responsibility 3.5 Dangers 3.5 Dangers Basic Information Information concerning the various forms of danger that can arise during machine operation are found here. Basic safety instructions are found in this service manual at the beginning of each chapter in the section entitled 'Safety'. Warning instructions are found before a potentially dangerous task Safely dealing with sources of danger The following describes the various forms of danger that can occur during machine operation. Electricity Allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out work on electrical equipment according to electrical engineering regulations. Before commissioning or re-commissioning the machine, the user must ensure adequate protection against electric shock from direct or indirect contact. Before starting any work on electrical equipment: Switch off and lock out the power supply isolator and verify the absence of any voltage. Switch off any external power sources. These could be connections to floating contacts or electrical machine heating, for example. Use fuses corresponding to machine power. Check regularly that all electrical connections are tight and in proper condition. Forces of compression Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or death. The following information concerns work on components that could be under pressure. Close shut-off valves or otherwise isolate the machine from the distribution network to ensure that no compressed air can flow back into the machine. De-pressurise all pressurised components and enclosures. Do not carry out welding, heat treatment or mechanical modifications to pressurised components (e.g. pipes and vessels) as this affects the component's resistance to pressure. The safety of the machine is no longer ensured. Compressed air quality Never directly inhale compressed air. Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and/or for the processing of foodstuffs. Use compressor oil compatible with foodstuffs if compressed air can come into contact with them. Spring forces Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. Solenoid valves and check valves are spring-loaded. 16

27 3 Safety and Responsibility 3.5 Dangers Do not open or dismantle any valves. Rotating components Touching the fan while the machine is activated can result in serious injury. Do not open the enclosure while the machine is activated. Switch off and lock out the power supply disconnecting device and verify the absence of any voltage. Wear close-fitting clothes and a hair net if necessary. Make sure all covers and safety guards are in place and secured before re-starting. Temperature Do not touch hot components! These include, for example, compressor blocks, compressed air lines, coolers, motors and machine heaters. Wear protective clothing. If welding is carried out on or near the machine, take adequate measures to prevent sparks or heat from igniting oil vapours or parts of the machine. Noise Operate the machine only with intact sound insulation. Use hearing protection when appropriate. The pressure relief valve blowing off can be particularly loud. Operating fluids/materials Strictly forbid fire, open flame and smoking. Follow safety regulations when dealing with oils, lubricants and chemical substances. Avoid contact with skin and eyes. Do not inhale oil mist and vapours. Do not eat or drink while handling cooling and lubricating fluids. Keep suitable fire extinguishing agents ready for use. Use only KAESER approved operating materials. Unsuitable spare parts Use only spare parts approved by the manufacturer for use in this machine. Unsuitable spare parts compromise the safety of the machine. Use only genuine KAESER replacement parts on pressure bearing parts. Conversion or modification of the machine Do not permit conversion or modification of the machine as this can compromise function and safe working. 17

28 3 Safety and Responsibility 3.5 Dangers Extending or modifying the compressor station If a compressor station is to be extended or changed, check the blow-off capacity of the pressure relief valves on air receivers and pipework before installing the new devices. Pressure relief valves of insufficient blow off capacity must be replaced by valves with a higher capacity Safe machine operation Information on safe conduct when handling the machine is found here. Transport Use suitable lifting gear that conforms to local safety regulations. Allow transport only by personnel trained in the safe movement of goods. Attach lifting gear only to suitable lifting points. Note the centre of gravity to avoid danger of the machine tipping over. Make sure the danger zone is clear of personnel. Installation Install the machine in a suitable compressor room. If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and splashing water. Do not operate in areas in which specific requirements with regard to explosion protection are in force. For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres". Ensure adequate ventilation. Ensure that required ambient conditions are maintained with regard to: Ambient temperature and humidity Clean inlet air with no damaging contaminants. Inlet air free of explosive or chemically unstable gases or vapours. inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulphide. Do not position the machine in warm exhaust air from other machines. Ensure accessibility so that all work on the machine can be carried out without danger or hindrance. Decommissioning, storage, disposal Drain out fluids and dispose of according to environmental regulations. These include, for example, lubricating oil and compressor oil. Dispose of the machine in accordance with local environmental regulations Organisational Measures Designate personnel and their responsibilities. 18

29 3 Safety and Responsibility 3.6 Safety Devices Give clear instructions on reporting faults and damage to the machine. Give instructions on fire reporting and fire-fighting measures Danger Areas The table gives information on the areas dangerous to personnel. Only authorised personnel may enter these areas. Activity Danger area Authorised personnel Transport Within a 1 m radius of the machine. Installation personnel for transport preparation. Installation Beneath the lifted machine. Within the machine. Within 1 m radius of the machine and its supply cables. No personnel during transport. No personnel! Installation personnel Operation Within a 1 m radius of the machine. Operating personnel Maintenance Within the machine. Within a 1 m radius of the machine. Maintenance personnel Tab. 27 Danger Areas 3.6 Safety Devices Various safety devices ensure safe working with the machine. Do not change, bypass or disable safety devices. Check safety devices for correct function regularly. Do not remove or obliterate labels and notices. Ensure that labels and notices are clearly legible. Further information More information on safety devices is contained in chapter4, section Safety Signs The diagram shows the positions of safety signs on the machine. The table lists the various safety signs used and their meanings. 19

30 3 Safety and Responsibility 3.8 Information signs Fig. 1 Location of safety signs Item Sign Meaning 1 Danger of fatal injury from electric shock! 2 Hot surface! Before starting any work on electrical equipment: Switch off and lock out the power supply disconnecting device and check that no voltage is present. Risk of burns caused by contact with hot components Do not touch the surface. Wear long-sleeved garments (not synthetics such as polyester) and protective gloves. Tab. 28 Safety Signs 3.8 Information signs The table lists the various information signs used and their meanings. Symbol Meaning Take heed of safety instructions and the service manual. Maintain the air filter regularly. Check the oil level regularly and change the oil at the correct intervals. Tab. 29 Information signs 20

31 3 Safety and Responsibility 3.9 Emergency situations 3.9 Emergency situations Correct fire fighting Suitable extinguishing agents foam carbon dioxide sand or earth Usuitable extinguishing media Strong jet of water 1. Keep calm. 2. Give the alarm. 3. If possible: Isolate the machine from all power phases. 4. To ensure safety: warn persons in danger help incapacitated persons close the doors 5. When trained accordingly: Attempt to extinguish the fire Remove any compressor oil from your person. Eye contact: Rinse eyes thoroughly with lukewarm water and seek medical assistance. Skin contact: Wash off immediately Warranty This service manual contains no independent warranty commitment. Our general terms and conditions of business apply with regard to warranty. A condition of our warranty is that the machine is used for the purpose for which it is intended under the conditions specified. Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application. In addition, we accept no warranty obligation for: the use of unsuitable parts or operating materials, unauthorised modifications, incorrect maintenance, incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. Obtain confirmation from KAESER that your specific operating conditions are suitable. 21

32 3 Safety and Responsibility 3.11 Environmental Protection 3.11 Environmental Protection Store and dispose of operating materials and replaced parts in accordance with local environmental protection regulations. Observe relevant national regulations. This applies particularly to parts contaminated with compressor oil. Drain condensate into a receptacle. Obtain advice from KAESER on suitable drains and receptacles. Do not allow operating materials to escape to the environment or into the sewage system. 22

33 4 Design and Function 4.1 Outline of the machine 4 Design and Function 4.1 Outline of the machine Main components Fig. 2 List of main components 1 Compressor block 2 Drive motor 3 Sound enclosure Function Fig. 3 Machine layout 1 Air filter 2 Compressor block 2a 1-cylinder block 2b 2-cylinder block 3 Electric motor 4 Air cooler (depending on machine) 5 Fan with guard (depending on machine) 6 Cylinder or collecting pipe relief valve 7 Oil filler port 8 Oil sight glass 9 Oil drain plug 10 Arrow showing direction of rotation 11 Compressed air outlet 23

34 4 Design and Function 4.2 Options Machine Atmospheric air is drawn through a filter into the compression chamber of the block. The air is drawn in during the downward stroke of the piston. It is compressed during the upward stroke. The compressed air passes through the cooling pipe or cooler to the compressed air outlet. 4.2 Options The options available for your machine are described below Option C5 Oil level monitoring The oil level in the machine is monitored automatically. The machine is automatically shut down if the oil level falls below minimum. Fig. 4 Oil level monitoring 1 Oil level monitoring Option H1 Adjustable machine mountings These mounts allow the machine to be anchored firmly to the floor. Fig. 5 Adjustable machine mountings 1 Adjustable machine mountings 2 Threaded joint 24

35 4 Design and Function 4.2 Options Option H9 Silenced air filter The air filter reduces the noise level of the machine. It also cleans the inlet air. Fig. 6 Silenced air filter 1 Air filter element Option H10 Air filter with plastic casing This air filter is suitable for unfavourable ambient conditions. It also cleans the inlet air. Fig. 7 Air filter with plastic casing 1 Air filter element Option H14 Castors For easy moving the machine. Fig. 8 Castors 1 Castors 2 Wheel stops 25

36 4 Design and Function 4.3 Operating modes and control modes Option H20 Bolt-on machine mounts for mounting on tank For the vibration-free and quiet installation of the machine on, e.g., a compressed air tank. Fig. 9 Bolt-on machine foot 1 Bolt-on machine foot 2 Threaded joint 4.3 Operating modes and control modes Operating modes There are two operating modes: LOAD: The compressor block delivers compressed air. The compressor motor runs under full load. STANDSTILL No air is compressed. The check valve to be installed by the user prevents already compressed air flowing back into the compressor. The compressor block is vented. The drive motor is stopped External control unit An external control unit is required to activate the drive motor, the pressure switch, the solenoid valve, and the oil level monitoring (Option C5). This enables an unloaded starting of the machine. The control unit is not provided with the machine and is to be supplied by the user. The following points have to be observed: Install the control unit to EN specifications. Select the components to suit the motor power. Connect the solenoid valve such that it first closes when the drive motor has run up to speed. 4.4 Safety devices The following safety devices are provided and may not be modified in any way. 26

37 4 Design and Function 4.4 Safety devices Pressure relief valve The pressure relief valve protects the machine from excessive pressure. It is factory set. Enclosures and covers Enclosures and covers over moving parts and electrical connections protect against accidental contact Safety and regulating devices The following safety and regulating devices are to be installed by the user. Pressure relief valve The pressure relief valve protects the air receiver against excessive pressure. Check valve The check valve prevents the flow of compressed air from the air receiver back to the compressor block when the machine is stopped. Pressure switch The pressure switch regulates the working pressure of the air network. The pressure switch toggles the compressor between LOAD and STANDSTILL to maintain a constant working pressure. Pressure gauge The gauge monitors working pressure. It should be chosen to accommodate the maximum working pressure. Motor overload protection The motor protection device shuts down the machine: in the case of a phase drop-out overload, if the ambient temperature becomes too high, if the compressor block seizes, if the mains voltage fluctuates outside limits. AC motors may be operated only with correctly set motor protection switch or overload relay. The warranty is void without motor protection. Further information See chapter 6.5 for an example of the arrangement of the safety installations to be installed by the user. Safety signs The machine has been delivered with all necessary safety signs. After installation in a system, the user is obliged to add any necessary safety-related labels. 27

38 4 Design and Function 4.5 Accessories 4.5 Accessories To reduce the machine's noise emission, it can be retrospectively fitted with a sound enclosure. Further information Instructions on installation of a sound enclosure can be found in chapter

39 5 Installation and Operating Conditions 5.1 Safety 5 Installation and Operating Conditions 5.1 Safety Strictly forbid fire, open flame and smoking. If welding is carried out on or near the machine, take adequate measures to prevent sparks or heat from igniting oil vapours or parts of the machine. The machine is not explosion-proof: Do not operate in areas in which specific requirements with regard to explosion protection are in force. For instance, the requirements of ATEX directive94/9/ec "Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres". Ensure that required ambient conditions are maintained with regard to: ambient temperature and humidity, clean inlet air with no damaging contaminants, inlet air free of explosive or chemically unstable gases or vapours, inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulphide. Keep suitable fire extinguishing agents ready for use. 5.2 Installation conditions Determining location and clearances The clearances given are recommended and ensure unhindered access to all machine parts. Please consult KAESER if you cannot comply with these recommendations. Precondition The floor must be level, firm and capable of bearing the weight of the machine. 29

40 5 Installation and Operating Conditions 5.2 Installation conditions Fig. 10 Recommended machine placement and dimensions [mm] A Exhaust fan Z Air inlet aperture CAUTION Ambient temperature too low. The reduced lubrication properties of oil that is too viscous can result in damage when starting the machine. Ensure that the temperature of the machine is at least +3 before starting. Make sure the compressor room is adequately heated. 1. If installed outdoors, the machine must be protected from frost, direct sunlight, dust and rain. 2. Ensure adequate lighting so that all work on the machine can be carried out without danger or hindrance Ensuring adequate ventilation If the ventilation is insufficient, a partial vacuum can be created in the room. 1. Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine and exhaust fan. 2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually open. 3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely through the room. Further information See chapter 2.6 for ventilation aperture dimensions. 30

41 5 Installation and Operating Conditions 5.2 Installation conditions Operation in a compressed air network When the machine is connected to a compressed air network, the network working pressure may not exceed the permissible working pressure of the machine. Please contact KAESER for advice. 31

42 6 Installation 6.1 Safety 6 Installation 6.1 Safety Here you will find instructions for safe initial start-up of the machine. Warning instructions are located before a potentially dangerous task. Basic safety instructions 1. Follow the instructions in chapter "Safety and Responsibility". 2. Have installation work carried out by authorized installation personnel only. 3. Before switching on, make sure that: no personnel are working on the machine, all panels are in place and secured. Working on live components 1. Work on electrical equipment may only be carried out by authorized electricians. 2. Switch off and lock out the power supply disconnecting device and check that no voltage is present. Working on pressure systems 1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine. 2. Vent all pressurized components and chambers completely. 3. The pressure gauge on the machine must read 0 bar. Working on the drive system 1. Switch off and lock out the power supply disconnecting device and check that no voltage is present. 2. Replace and secure all enclosure panels before starting the machine. Further information See chapter regarding authorized personnel. See chapter 3.5 regarding hazards and their avoidance. 6.2 Reporting Transport Damage 1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. 6.3 Fitting the antivibration mounts CAUTION There is a danger of tipping because of the centre of gravity and weight of the machine. Use slings to lift the machine. 32

43 6 Installation 6.4 Compressed Air Connection Fig. 11 Fitting the antivibration mounts 1 Antivibration mount 2 Hexagonal nut Remove the wooden frame from the base plate. Secure the antivibration mounts to the base plate with hexagon nuts. 6.4 Compressed Air Connection Precondition The compressed air system is vented completely to atmospheric pressure. Fig. 12 Compressed air connection 1 Flexible hose 2 Shut-off valve 3 Check valve A shut off valve and check valve must be installed by the user in the connection line. Make the connection to the air main by a flexible hose. 6.5 Typical installation for safety and regulating devices The following example does not refer to an actual application. Safety and regulating devices ensure a safe machine operation. 33

44 6 Installation 6.6 Connecting the Power Supply Fig. 13 Suggested Safety and Control Devices 1 Air receiver 2 Pressure switch 3 Check valve 4 Flexible hose to the machine 5 Pressure relief valve 6 Test flange 7 Pressure gauge 8 Compressed air outlet 9 Compressed air inlet 10 Shut-off valve for condensate drainage 11 Nozzle (machine-dependent) Install safety and regulating devices at the user side of the compressed air network or directly on the compressed air container. 6.6 Connecting the Power Supply Precondition The machine is disconnected from all power supply phases. The disconnecting device is locked in the off position. A check has been made that no voltage is present. 1. Have the power supply connected only by authorized installation personnel or an authorized electrician. 2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example or DIN VDE 0100) and in national accident prevention regulations (BGV A3 in Germany). In addition, observe the regulations of the local electricity supplier. 34

45 6 Installation 6.7 Options 3. Check the permitted disconnect time for the overload protection cut-out if a fault arises. 4. Use conductor dimensions and fuse ratings in accordance with local regulations (in Germany VDE 0100 parts 430 and 523, for example). 5. The user must provide the machine with a lockable power supply disconnecting device. This could be, for example, a load disconnect switch with fused input. If a circuit breaker is used it must be suitable for the motor starting characteristics. Machines with a total power rating of up to 3 kw and rated current of up to 16 amps may be provided with a simple cable and plug power supply connection. DANGER Danger of fatal injury from electric shock! Switch off and lock out the power supply disconnecting device and check that no voltage is present. 6. Connect the machine to the power supply. 6.7 Options The options available for your machine are described below Option C5 Oil level monitoring The oil level monitor does not relieve the user of the obligation to visually check the oil level at regular intervals. The contact in the oil level monitor is wired at the factory as a normally open contact. Oil level rises falls Electrical contact closes opens Tab. 30 Precondition Oil level monitor The supply disconnecting device is switched off, the device is locked off, the absence of voltage has been verified. DANGER Electric shock! Danger of fatal injury caused by contact with live components. Switch off and lock out the power supply disconnecting device and verify the absence of voltage. 35

46 6 Installation 6.7 Options Fig. 14 Oil level monitor connections 1 Compressor block 2 Oil level monitor Oil level monitoring and direct online starting Machines with direct online starting and an under-voltage cut-out on the pressure switch require additional control and connection components. 1. Electrical connections to be made by the user. 2. The machine is switched off by the pressure switch. Oil level monitoring and star-delta starting Machines with star-delta starting require additional control and connection parts and an external control unit. The oil level monitor must be linked with the external controller so that the machine is shut down if oil falls below the set minimum level. 1. The user is to make the connection to the power supply or the connection to an external control unit. 2. The machine is switched off by the external controller Float switch The float switch has been set at the factory as follows: The machine shuts down when the oil falls to its minimum permissible level. The tip of the red arrow is visible for 2 mm. Check the setting and adjust, if required Adjusting the setting Adjust the switching point by moving the sensing contact slightly along an arrow. You may fine-adjust the switching point to the length of the arrow. Moving towards the arrow head lowers the oil level point at which the sensor triggers. Moving away from the arrow head raises the oil level point at which the sensor triggers. 36

47 6 Installation 6.7 Options Fig. 15 Changing the oil level monitoring setting 1 Switch cover 2 Screw 3 Red arrow 4 Sensing contact 1. Switch off the machine. 5 Adjustment range 6 Higher oil level 7 Lower oil level DANGER Electric shock! Danger of fatal injury caused by contact with live components. Switch off and lock out the power supply disconnecting device and verify the absence of voltage. 2. Open the switch cover. 3. Loosen the screw and move the sensing contact. 4. Re-tighten the screw. 5. Close the cover until it latches. 6. Switch on the machine. 37

48 6 Installation 6.7 Options Option H1 Anchoring the Machine Fig. 16 Securing the bolt-on machine mounts 1 Bolt-on machine mountings 2 Threaded joint Use appropriate fixing bolts to anchor the machine. Further information Details of the anchoring holes are shown in the dimensional drawing in chapter Option H20 Mounting the machine on a compressed air tank Fig. 17 Securing the bolt-on machine mounts 1 Bolt-on machine foot 2 Threaded joint 3 Hex-head bolt 4 Hexagon nut Use appropriate fixing bolts to anchor the machine. Further information Details of the anchoring threads are shown in the dimensional drawing in chapter

49 6 Installation 6.8 Retrofitting the Sound Enclosure (accessory) 6.8 Retrofitting the Sound Enclosure (accessory) The sound enclosure is supplied already assembled. The enclosure must be dismantled for fitting to the machine Dismantling the sound enclosure Note how the parts fit together. Open the snap fastener and unscrew the enclosure from the base plate Vent the machine (depressurize) The machine must be isolated from the air system and completely vented before undertaking any work on the pressure system. Precondition The power supply disconnecting device is switched off. The disconnecting device is locked in the off position. A check has been made that no voltage is present. The machine is completely depressurised (pressure gauge reads 0 bar). The machine has cooled down. The user's shut-off valve between the machine and the air network is closed. Fig. 18 Removing the air filter 1 Compressor block 2 Hexagonal nut 3 Machine mounting pad 4 Bracket 5 Air filter 6 Hexagonal nut DANGER Dangerous voltage! There is danger of fatal injury caused by contact with live components. Switch off and lock out the power supply disconnecting device and check that no voltage is present. 1. Remove the cable from the motor terminal box. 39

50 6 Installation 6.8 Retrofitting the Sound Enclosure (accessory) WARNING Compressed air! Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly or uncontrolled. Make sure all components and vessels are depressurized and the user's pressure gauge reads 0 bar. 2. Disconnect the hose line from the check valve. 3. Loosen the hexagon nuts and exchange antivibration pads for machine mountings. 4. Removing the air filter 5. Screw the elbow to the cylinder head and the filter to the elbow Fitting the Sound Enclosure Precondition The antivibration pads are removed and machine mountings fitted. The air filter is fitted. Fig. 19 Fitting the Sound Enclosure 1 Compressor block 2 Base plate 3 Machine mounting pad 4 Air cooler 5 Hose 6 User's check valve 7 Sheet metal ring 8 Pre-cut foam 9 Air inlet soundproofing box 10 Sound enclosure 11 Snap fastener 12 Panel (exhaust louver) 1. Set the machine on the base plate and secure the machine mountings. 2. Fix the sheet metal ring to the cooler with the fixings provided and slide the foam collar over the ring. 3. Lead cables and pipes through the holes provided and connect up. 4. Fix the enclosure to the base plate. 5. Screw the air inlet soundproofing box to the enclosure, hang the panel with exhaust louvers in the enclosure and fix with the snap fasteners. 40

51 7 Initial Start-up 7.1 Safety 7 Initial Start-up 7.1 Safety Here you will find instructions for safe initial start-up of the machine. Warning instructions are located before a potentially dangerous task. Basic safety instructions 1. Follow the instructions in chapter "Safety and Responsibility". 2. Have the initial start-up carried out by authorized installation personnel only. 3. Before switching on, make sure that: no personnel are working on the machine, all panels are in place and secured. Working on live components 1. Work on electrical equipment may only be carried out by authorized electricians. 2. Switch off and lock out the power supply disconnecting device and check that no voltage is present. Working on pressure systems 1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine. 2. Vent all pressurized components and chambers completely. 3. The pressure gauge on the machine must read 0 bar. Working on the drive system 1. Switch off and lock out the power supply disconnecting device and check that no voltage is present. 2. Replace and secure all enclosure panels before starting the machine. Further information See chapter regarding authorized personnel. See chapter 3.5 regarding dangers and their avoidance. 7.2 Instructions to be observed before commissioning or recommissioning Incorrect or improper initial start-up can cause damage to the machine. 41

52 7 Initial Start-up 7.3 Checking installation and operating conditions Only a competent technician may carry out initial start-up. Special measures for start-up after storage Storage period longer than Action 12 months Change the Compressor Oil Have the motor bearings checked by an authorized KAESER Service Technician. 36 months Have the overall technical condition checked by an authorized KAESER Service Technician. Tab. 31 Re-commissioning after storage 7.3 Checking installation and operating conditions Check and confirm all the items in the checklist before first start-up of the machine. To be checked Are the operators fully conversant with safety regulations? Have all the positioning conditions been complied with? 5 Is a user-supplied lockable power supply disconnection device installed? Does the power supply conform to the specifications on the nameplate? 2.1 Are the power supply cable conductor diameters and fuse ratings adequate? Have all electrical connections been checked for tightness? (Repeat check after 50 operating hours) Are the user's shut-off and check valves fitted to the compressed air outlet? Is the connection to the air main made with a flexible hose? 6.4 Sufficient oil in the crankcase? (oil in the sight gauge red zone) The oil must be changed after 50 operating hours Is the user's motor protection device adjusted correctly with regard to the engine power? See chapter Oil level monitor connected? Is the machine securely bolted to the floor or at the compressed air tank? Are all access doors closed and latched and all removable panels in place and secured? (sound enclosure) / Complied? Tab. 32 Checklist of installation conditions 42

53 7 Initial Start-up 7.4 Motor overload protection 7.4 Motor overload protection The machine should only be operated with a correctly adjusted motor overload protection switch to protect the motor from overloading. A motor overload protection switch that is set too high provides no protection. Incorrect setting can lead to irreparable damage Checking the motor protection device 1. Read the rated motor current from the nameplate and calculate the correct protection setting. 2. Check the motor protection setting. 3. Adjust the protection setting, if necessary. Direct online starting The machine starts directly and is controlled by the user's pressure switch. The pressure switch switches the machine on and off as necessary to hold pressure within the set limits. The overload protection device setting can be 10 % higher than the rated motor current to prevent it from being triggered by voltage fluctuations, temperature influences or component tolerances. 1. Switch the machine on with the user's pressure switch. Was the machine shut down by the motor protection cut-out? Allow the motor to cool down. Switch the machine on. See also chapter 8. Star-delta starting In the star-delta configuration the phase current is fed via the motor overload protection device. This phase current is 0.58 times the rated motor current (see motor nameplate). The overload protection device setting can be 10 % higher than the rated phase current to prevent it from being triggered by voltage fluctuations, temperature influences or component tolerances. 1. Switch the machine on from the external control unit. Was the machine shut down by the motor protection cut-out despite correct setting? Contact the KAESER Service. 7.5 Checking direction of rotation The machine is designed for a clockwise phase sequence. Ideally, the direction of phase rotation should be measured with a phase sequence meter. Alternatively, start the machine very briefly and observe the direction of rotation of the motor cooling fan. 1. Check the direction of phase rotation with a phase sequence meter. 2. If the direction is incorrect, reverse supply phases L1 and L2. You have no phase sequence meter? Switch the machine on and off again the moment the drive motor begins to turn. Check the direction of rotation against the arrow on the fan cowl. If the direction is incorrect, reverse L1 and L Starting the Machine for the First Time Precondition No personnel are working on the machine. All panels are in place and secured. 43

54 7 Initial Start-up 7.7 Measuring the air receiver filling time 1. Open the shut-off valve to the air system. 2. Switch on the power supply disconnecting device. The machine switches to LOAD and delivers compressed air. The machine should be observed during the first few hours in operation in order to detect any faults. After the first 50 operating hours, the following must be carried out: Check that all electrical connections are secure. Change the oil. 7.7 Measuring the air receiver filling time Measuring the time the compressor takes to fill the air receiver when new can be useful in checking the machine's performance at a later date. Precondition Machine at operating temperature. 1. Close the shut-off valve to the air main. 2. Switch on the power supply disconnecting device. 3. Measure the air receiver charging time. 4. Enter the charging time, the receiver size and machine model in the table. Machine model Air receiver size (litres) Receiver charging time from 3 9 bar [min/s] Tab. 33 Air receiver charging time 44

55 8 Operation 8.1 Switching on and off 8 Operation 8.1 Switching on and off Always switch the machine on and off with the «ON/OFF» switch. Depending on the starter type, the «ON/OFF» switch may be found on the user's pressure switch or controller. The following starting modes are available: Direct start - the machine is activated and deactivated at the pressure switch. Direct start with solenoid valve the machine is activated and deactivated on the controller. Star-delta start - the machine is activated and deactivated at the controller. Fig. 20 Switching on and off 1 «ON/OFF» switch at the pressure switch 2 «ON/OFF» switch at the controller DANGER Automatic restart! Serious injury is possible. The machine restarts automatically when power is restored after a power cut. Make sure that no one is working on the machine. Switch the machine on and off according to the start configuration Direct online starting Precondition A power supply disconnecting device has been installed by the user. No personnel are working on the machine. All panels are in place and secured. The machine temperature is at least +3 C. Switching on WARNING Compressed air! Serious injury is possible. Never direct compressed air at persons or animals. Make sure that no one is working on the machine. 1. Switch on the power supply isolating device. 2. Switch on the compressor at the user's pressure switch. 45

56 8 Operation 8.1 Switching on and off Result The machine starts as soon as network pressure is lower than the cut-out pressure. Switching off 1. Switch off the compressor at the user's pressure switch. 2. Switch off and lock out the power supply isolating device Direct online start with solenoid valve Precondition The user has connected a control unit. A power supply isolating device has been installed by the user. No personnel are working on the machine. All panels are in place and secured. The machine temperature is at least +3 C. Switching on DANGER Compressed air! Serious injury is possible. Never direct compressed air at persons or animals. Make sure that no one is working on the machine. 1. Switch on the power supply isolating device. 2. Switch on the machine from the external control unit. Result The machine starts as soon as network pressure is lower than the cut-out pressure. Switching off 1. Switch off the machine from the external control unit. 2. Switch off and lock out the power supply isolating device Star-delta starting Precondition The user has connected a control unit. A power supply isolating device has been installed by the user. No personnel are working on the machine. All panels are in place and secured. The machine temperature is at least +3 C. Switching on DANGER Compressed air! Serious injury is possible. Never direct compressed air at persons or animals. Make sure that no one is working on the machine. 1. Switch on the power supply isolating device. 2. Switch on the machine from the external control unit. 46

57 8 Operation 8.1 Switching on and off Result The machine starts as soon as network pressure is lower than the cut-out pressure. Switching off 1. Switch off the machine from the external control unit. 2. Switch off and lock out the power supply isolating device. 47

58 9 Fault Recognition and Rectification 9.1 Basic Information 9 Fault Recognition and Rectification 9.1 Basic Information The alarm indications valid for your machine are dependent on the individual equipment. 1. Do not attempt fault rectification measures other than those given in this manual. 2. Inform KAESER Service if the fault cannot be rectified by the measures suggested. 9.2 Alarms Fault Possible cause Action Machine does not start. Machine starts with difficulty. Fuse blown or circuit breaker tripped. Defective contact in the user's pressure switch. Motor overload protection has tripped. Drive motor defective: bearing damage or windings shorted. Compressor block defective. The oil level monitor (option C5) has triggered. The solenoid valve is not opening. Bearing damage. Piston seized due to insufficient or incorrect oil. Fault in the power supply. Oil level too high. Check motor connections and fuses (circuit breakers). Replace pressure switch. Allow the motor to cool down. Contact KAESERservice. Contact KAESERservice. Check undervoltage trip in the user's pressure switch or the controller. Check the connection to the solenoid valve. Change the solenoid valve. Contact KAESERservice. Contact KAESERservice. Check power supply. Drain out some oil. Machine runs hot. Ambient temperature too high. Reduce the ambient temperature. Motor overload protection trips out after a short time. Wrong direction of rotation. Fan cannot draw air freely. Swap the L1 and L2 connections to the drive motor. Ensure unrestricted flow of air to the fan. Valve plate leaking air or coked. Check or clean the valve plate. Outlet valve reed broken. Fault in the power supply. Motor fault. Replace valve plate. Check power supply. Contact KAESERservice. 48

59 9 Fault Recognition and Rectification 9.2 Alarms Fault Possible cause Action Motor overload protection trips out after a long time. The machine runs continuously but maximum pressure is not reached. Machine cuts in and out too often. Current too high because of low supply voltage. Air filter clogged. Check power supply cable conductor cross-sections. Check and tighten connection terminals. Clean or change the air filter. Valve plate leaking air or coked. Check or clean the valve plate. Outlet valve reed broken. Machine leaks air. Leakage from an air consumer connected to the air system. The air demand is greater than the machine's air delivery capacity. Solenoid valve blows off continuously. Solenoid coil is defective. External air receiver filled with condensate. Machine switches off. The oil level monitor (option C5) has triggered. Air leaks from the user's pressure switch while the machine is running. Whistling sound from the cylinder head. The pressure relief valve blows off before the cut-out pressure is reached. Pressure relief valve on the air cooler blows off prematurely. Defective switch diaphragm. Replace valve plate. Seal leak or replace leaking part. Check possible leakage points. Use a larger machine. Change the solenoid valve. Tapp ut kondensat. Top up the oil. Replace the pressure switch. The venting valve is not closing. Clean or replace the venting valve. Remove the screws. Gasket defective. Pressure switch incorrectly set. Valve spring defective. Dirt or foreign bodies on the valve seat. Cooler clogged. Cooler pipe blocked with scale. Tighten screws Replace gasket. Check pressure switch setting. Replace the pressure relief valve. Let the pressure relief valve blow off briefly. Clean the radiator. Machine uses too much oil. Viscosity too low. Fill with oil specified in the service manual. Piston rings already worn or damaged after only a short operating period. Crankcase venting defective. Piston rings worn or broken. Dirty oil. Clean or renew the crankcase vent. Contact KAESERservice. Fit finer air inlet filter. Tab. 34 Faults and remedies 49

60 10 Maintenance 10.1 Safety 10 Maintenance 10.1 Safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are found before a potentially dangerous task. Basic safety instructions. 1. Follow the instructions in chapter 'Safety and Responsibility'. 2. Maintenance work may only be carried out by authorized personnel. 3. Before switching on, make sure that: no personnel are working on the machine, all panels are in place and secured. Working on live components 1. Work on electrical equipment may only be carried out by authorized electricians. 2. Switch off and lock out the power supply disconnecting device and check that no voltage is present. Working on pressure systems 1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine. 2. Vent all pressurized components and chambers completely. Working on the drive system 1. Switch off and lock out the power supply disconnecting device and check that no voltage is present. 2. Replace and secure all enclosure panels before starting the machine. Further information See chapter regarding authorized personnel. See chapter 3.5 regarding dangers and their avoidance Maintenance Schedule Logging maintenance work The maintenance intervals given are those recommended for average operating conditions. Adjust the maintenance intervals with regard to local installation and operating conditions. Keep a log of all maintenance and service work. This enables the frequency of individual maintenance tasks and deviations from our recommendations to be determined. Further information A prepared list is provided in chapter

61 10 Maintenance 10.2 Maintenance Schedule Regular maintenance tasks When operating conditions are unfavourable (e.g. dusty atmosphere) or when the equipment is in constant use, maintenance tasks must be carried out more frequently (shorter intervals). Interval Maintenance task See chapter Daily or every 24 operating hours Check the oil level* 10.8 Every 500 h Carry out air filter maintenance 10.4 / 10.5 / 10.6 Annually Check that all electrical connections are tight. Every 3000 h or every 2 years at the latest Variable, see table 36 h = operating hours * not applicable for Option C5 Check the pressure relief valve Clean the solenoid valve Change the solenoid valve Change the compressor oil Tab. 35 Regular maintenance tasks Oil change interval Duty cycles and ambient conditions are important criteria for the number and length of the oil change intervals. Advice can be obtained from KAESER Service on determining suitable changing intervals. Check operating conditions and adjust intervals as necessary; log the results in table 36 for future reference. Maximum permissible oil change interval [operating hours/years] Compressor oil Favourable operating conditions* My operating conditions SAE 5 W /2 VDL /1 FGP 1000/2 S /1 * Cool to moderate ambient temperatures, low humidity, low to average duty cycle. Tab. 36 Oil change intervals Regular service tasks Only an authorised KAESER Service Technician should carry out service work. 51

62 10 Maintenance 10.3 Maintaining the air cooler or fan guard When operating conditions are unfavourable (e.g. dusty or humid atmosphere) or when the equipment is in constant use, have the service work carried out more frequently (shorter intervals). Interval Every 2 years at least Up to 3000 h Up to 12,000 h up to 12,000 h, every three years at the latest up to 36,000 h, every six years at the latest h = operating hours Service task Change the air filter element Have cylinder head and valves checked. Have the machine generally overhauled. Have motor bearings checked. Replace prepared hoses Tab. 37 Regular service tasks 10.3 Maintaining the air cooler or fan guard According to machine model, it either has an air cooler of a fan guard. Clogging causes overheating and machine damage. Regular cleaning ensures reliable cooling of the machine and the compressed air. The frequency is mainly dependent on local operating conditions. Material Precondition Brush Vacuum cleaner Face mask (as required) The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. Fig. 21 Cleaning the air cooler or fan guard 1 Compressed air cooler 2 Fan with guard 3 Brush 52

63 10 Maintenance 10.4 Air filter maintenance Cleaning the air cooler or fan guard Do not use sharp objects to clean the air cooler or fan guard. It could cause damage. Avoid creating clouds of dust. Dry brush the air cooler or fan guard and safety screen using a vacuum cleaner to suck up the dirt. The air cooler or fan guard can't be cleaned thoroughly? Have stubborn clogging removed by an authorized KAESER Service Technician Air filter maintenance The air filter insert is made of fibre mesh. Material Precondition Compressed air for blowing out Solvent cleaner Spares as required The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. Fig. 22 Air filter maintenance 1 Air filter 2 Inlet air opening 3 Air filter element 4 Retaining clip 5 Cover 1. Unscrew the air filter. 2. Release the retaining clip and take off the cover. 3. Blow out the cover and the insert with dry compressed air (<5 bar). 4. Clean the housing and sealing faces. 5. Wet the wire mesh insert lightly with oil after cleaning. If the insert is heavily clogged, clean with a solvent-based fluid or steam blaster. Observe safety regulations. Replace the air filter if it has already been cleaned a number of times. 53

64 10 Maintenance 10.5 Air filter (noise absorbing) maintenance 6. Position the cover over the insert and close the retaining clips. 7. Mount the air filter again. The filter air inlet must face downwards. 8. Switch on the power supply disconnecting device Option H9 Air filter (noise absorbing) maintenance Check that all sealing surfaces match each other. The use of an unsuitable air filter element can permit dirt to ingress the pressure system and cause damage to the machine. Material Precondition Compressed air for blowing out Spares as required The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. Fig. 23 Air Filter (noise absorbing) Maintenance 1 Air filter element 2 Inlet air opening 3 Retaining clip 4 Cover 54

65 10 Maintenance 10.6 Air filter (with plastic casing) Cleaning the air filter element by tapping. 1. Release the retaining clip and take off the cover. 2. Withdraw the filter element. 3. Tap the element at the front a number of times with the palm of the hand. 4. Clean the housing and sealing faces. 5. Replace the filter element. 6. Position the cover and close the retaining clips. 7. Switch on the power supply disconnecting device. Cleaning the filter element with compressed air 1. Release the retaining clip and take off the cover. 2. Withdraw the filter element. 3. Use dry compressed air at not more than 5 bar to blow dirt from the air filter element from inside to outside. 4. Clean the housing and sealing faces. 5. Replace the filter element. 6. Position the cover and close the retaining clips. 7. Switch on the power supply disconnecting device Option H10 Air filter (with plastic casing) Check that all sealing surfaces match each other. The use of an unsuitable air filter element can permit dirt to ingress the pressure system and cause damage to the machine. Material Precondition Compressed air for blowing out Spares as required The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. Fig. 24 Air filter (with plastic casing) 1 Cover 2 Air filter element 3 Air filter housing 55

66 10 Maintenance 10.7 Drive Motor Maintenance Cleaning the air filter element by tapping. 1. Unscrew and remove the cover. 2. Withdraw the filter element. 3. Tap the element at the front a number of times with the palm of the hand. 4. Clean the housing and sealing faces. 5. Replace the filter element. 6. Replace the cover and screw down tight. 7. Switch on the power supply disconnecting device. Cleaning the filter element with compressed air 1. Unscrew and remove the cover. 2. Withdraw the filter element. 3. Use dry compressed air at not more than 5 bar to blow dirt from the air filter element from inside to outside. 4. Clean the housing and sealing faces. 5. Replace the filter element. 6. Replace the cover and screw down tight. 7. Switch on the power supply disconnecting device Drive Motor Maintenance The drive motor bearings are permanently greased and need no re-greasing. Have the motor bearings checked during service Checking the oil level The oil level can be read off on the oil sight glass. Precondition The machine is switched off. Fig. 25 Checking the oil level 1 Oil sight glass 2 Oil filler and crankcase vent Read off the oil level daily and before each start-up. Result Top up when the compressor oil level falls to the minimum mark. Top up the oil 56

67 10 Maintenance 10.9 Topping up the compressor oil 10.9 Topping up the compressor oil Material Precondition Compressor oil The power supply isolating device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. CAUTION The machine can be damaged by unsuitable oil. Never mix different types of oil. Never top up with a different type of oil to that already used in the machine. The type of compressor oil used is listed in table Remove the crankcase vent from the oil filler. 2. Top up to bring the oil to the correct level. 3. Replace the crankcase vent. 4. Start the machine and check the oil level again after about 2 minutes, topping up again, if necessary. 5. Switch off the machine and check visually for leaks Changing the compressor oil The initial charge of oil should be changed as specified in table 35. Drain the oil completely from the compressor block. If oil level monitoring is fitted: check its function as detailed in chapter Change the oil immediately if it becomes milky. This indicates a high condensate content. Contact KAESER Service if condensate is detected in the oil. Material Precondition Compressor oil Oil receptacle Machine at operating temperature. The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. CAUTION Danger of burning from hot components and scalding from escaping oil. Wear long-sleeved clothing and gloves. 57

68 10 Maintenance Testing the pressure relief valve Fig. 26 Changing the compressor oil 1 Oil filler port 2 Oil sight glass 3 Oil drain plug Draining the oil 1. Remove the crankcase vent from the oil filler. 2. Position the oil receptacle. 3. Remove the drain plug and allow oil to drain into the receptacle. 4. Replace the drain plug after making sure the gasket is not damaged. Dispose of the old oil in accordance with valid environmental protection regulations. Filling with oil 1. Fill with new oil to the maximum mark on the oil sight glass. 2. Replace the crankcase vent. 3. Start the machine and check the oil level again after about 2 minutes, topping up again, if necessary. 4. Switch off the machine and check visually for leaks Testing the pressure relief valve To check the valve activating pressure, it must be removed from the machine by a KAESER Service Technician and installed in a test rig. Further information See chapter 2.7 for the activating pressure of the valve Pressure relief valves on the cylinder head, collecting pipe and air cooler To prevent the relief valve from sticking it should be activated at regular intervals or at least once a year. 58

69 10 Maintenance Venting the machine (de-pressurising) The valve opens to protect the machine if the maximum permissible working pressure is exceeded. Never operate the machine without a correctly functioning pressure relief valve. Do not adjust the pressure relief valve. Precondition Machine running under LOAD. Fig. 27 Checking the pressure relief valves on the cylinder head, collecting pipe and air cooler 1 Pressure relief valve 2 Knurled knob A Cylinder head relief valve B C Pressure relief valve in the collecting pipe Air cooler relief valve WARNING The pressure relief valve may blow off at any time! Excessive noise is caused when the pressure relief valve blows off! There is danger of injury from bursting components and compressed air! Wear ear and eye protection. 1. Turn the knurled knob on the pressure relief valve anticlockwise until air blows off. 2. Then turn the knurled knob back to its original position. Pressure relief valve does not blow off? Have the defective relief valve replaced by KAESER Service Venting the machine (de-pressurising) Even when switched off, the machine is still under pressure from the air main to the user's check valve. The machine must be fully disconnected from compressed air network and de-pressurised before commencing any maintenance or service work requiring an opening of the pressure system. If no shut-off valve between machine and compressed air network is provided by the user, the entire air network must be vented. Precondition The supply isolating device is switched off, the device is locked off, a check has been made that no voltage is present. Machine is cooled down. 59

70 10 Maintenance Solenoid Valve Maintenance DANGER Compressed air! Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly. Close shut-off valves or otherwise isolate the machine from the compressed air network to ensure that no compressed air can flow back into the machine. 1. Close the user's shut-off valve between the machine and the air network. 2. Vent the machine via the user's venting valve or the solenoid valve integrated in the machine Solenoid Valve Maintenance The machine must be isolated from the air system and completely vented before undertaking any work on the pressure system. Material Precondition Compressed air for blowing out. Cleaning rags. Acid-free grease (e.g. Shell Retinax) Replacement part The mains disconnecting device is switched off. The disconnecting device is locked in the off position. A check has been made that no voltage is present. Machine is fully vented (no pressure). The user's shut-off valve between the machine and the air network is closed Clean the solenoid valve Fig. 28 Cleaning the solenoid valve 1 Solenoid valve 2 Screw 3 Solenoid 4 Armature 5 Spring 6 Piston 7 Body 8 Connecting socket 9 Arrow showing flow direction 1. Disconnect the connecting socket from the valve. 2. Undo the screw and carefully remove the coil. 60

71 10 Maintenance Cylinder head and valves 3. Clean the armature and piston. If the spring and O-ring are damaged or worn they must be replaced. 4. Reassemble the valve. 5. Open the user's shut-off valve between the machine and the air system. 6. Start the machine and visually check for leaks Changing the solenoid valve. Fig. 29 Changing the solenoid valve. 1 Solenoid valve 2 Fitting 3 Elbow with damper 4 Connecting socket 1. Disconnect the connecting socket from the valve. 2. Unscrew the elbow and damper. 3. Remove the defective valve. When mounting the solenoid valve make sure the flow direction is correct as indicated by the arrow on the body. 4. Screw the fitting and damper into the new solenoid valve using sealing tape. 5. Re-install the solenoid valve in the compressed air line. 6. Open the user's shut-off valve between the machine and the air system. 7. Start the machine and visually check for leaks Cylinder head and valves Material Compressed air for blowing out Cleaning cloths Brush Spares as required Checking the cylinder head and valves The condition of the valves can be assessed by measuring the air receiver charging time and comparing this with the charging time when the machine was new. 61

72 10 Maintenance Cylinder head and valves Precondition Machine at operating temperature. 1. Close the user's shut-off valve between the machine and the air network. 2. Start the machine and measure the receiver charging time. Result Further information The valves should be checked for coking if there is a significant difference between the measured charging time and the charging time when the machine was new. See chapter 7.7 for air receiver charging time measurement Cleaning the cylinder head and valves The machine must be isolated from the compressed air network and completely vented before undertaking any work on the pressure system. Precondition The supply disconnecting device is switched off, the device is locked off, the absence of voltage has been verified. The machine is fully vented (no pressure). The user's shut-off valve between the machine and the air network is closed. 1. Remove the cylinder head screws and lift off the head. 2. Remove the cap nut (if one is fitted). 3. Clean the cylinder head and valves. 4. After cleaning the cylinder head and valves, mount the head with the gasket and tighten the screws diagonally. Tightening torque for cylinder head screws Model Screws M A [Nm] Cap nut M A [Nm] EPC EPC EPC EPC EPC EPC Tab. 38 Screw tightening torques Starting the machine and carrying out a trial run 1. Open the user's shut-off valve between the machine and the air system. 2. Switch on the machine. 3. Switch off the machine and check visually for leaks. Significant malfunction in cylinder head and valves? Severe coking Have a KAESER Service Technician renew the cylinder head and valves. 62

73 10 Maintenance Document maintenance and service work Document maintenance and service work. Machine number: Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 39 Logged maintenance tasks 63

74 11 Spares, Operating Materials, Service 11.1 Note the Nameplate 11 Spares, Operating Materials, Service 11.1 Note the Nameplate The nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. Please give the information from the nameplate with every enquiry and order for spares Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are specifically selected for use in KAESER machines. WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuitable spares or operating fluids/materials. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the machine or impair its proper function. Personal injury may result from machine damage. Use only original KAESER parts and operating fluids/materials. Have an authorised KAESER Service Technician carry out regular maintenance. Fig. 30 Consumable parts 10 Air filter 20 Air filter element (silenced) 30 Air filter element (plastic housing) 40 Solenoid valve Machine Name Option Quantity Number Air filter 1/2* 10 Air filter element (silenced) H9 1/2* 20 Air filter element (plastic housing) H10 1/2* 30 Solenoid valve 1 40 Compressor oil SAE 5 W30 0.5l Compressor oil VDL l Compressor oil FGP 1.0l Compressor oil S l * depending on machine Tab. 40 Consumable parts 64

75 11 Spares, Operating Materials, Service 11.3 KAESER AIR SERVICE 11.3 KAESER AIR SERVICE KAESER AIR SERVICE offers: authorised service technicians with KAESER factory training, increased operational reliability ensured by preventive maintenance, energy savings achieved by avoidance of pressure losses, optimum conditions for operation of the compressed air system, the security of genuine KAESER spare parts, increased legal certainty as all regulations are kept to. Why not sign a KAESER AIR SERVICE maintenance agreement! Result Your advantage: lower costs and higher compressed air availability Service Addresses Addresses of KAESER agents are given at the end of this manual Spare Parts for Service and Repair Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER Service Technician. 65

76 12 Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: the machine is temporarily not needed, the machine is to be moved to another location, the machine is to be scrapped. Temporary de-commissioning Precondition The machine can be started at regular intervals. Run the machine once a week under load for at least 30 minutes to ensure corrosion protection. Permanent de-commissioning Precondition The machine must have run for at least 30 minutes before before permanent de-commissioning. The mains disconnecting device is switched off. The disconnecting device is locked in the off position. A check has been made that no voltage is present. Machine fully vented (no pressure). 1. Allow the machine to cool down completely. 2. Spray the valves and cylinder bore with Shell Ensis 20 preserving oil. The oil does not need to be removed when re-commissioning. 3. Disconnect all air and electrical connections. 4. Spray all contacts and terminals with a preservative (e.g. Rivalto, W.S.X.) Packing A wooden crate is required for overland transport to protect the machine from mechanical damage. Consult KAESER Service for advice on packing for sea or air transport. Material Precondition Desiccant Plastic sheeting Wooden transport crate The machine is decommissioned. Machine is dry and cooled down. 1. Wrap the machine in plastic sheeting. 2. Place sufficient desiccant (e.g. silica gel) inside the plastic sheeting Storage Moisture can lead to corrosion, particularly on the surfaces of the compressor block. 66

77 12 Decommissioning, Storage and Transport 12.4 Transporting Frozen moisture can damage components, diaphragms, valves and gaskets. Advice can be obtained from KAESER on storage and commissioning. CAUTION Moisture and frost can damage the machine. Prevent ingress of moisture and formation of condensation. Maintain a storage temperature of >0 C. Store the machine in a dry, frost-proof room Transporting Safety Weight and centre of gravity determine the most suitable method of transport. Precondition Transport only by fork truck or lifting gear with personnel trained in the safe transport of goods. Make sure the danger zone is clear Transporting with a forklift truck Precondition Machine must stand on a suitable transport medium (pallet). Fig. 31 Transporting with a forklift truck Drive the forks completely under the palette and lift carefully Transporting with a crane A suitable lifting frame ensures correct transportation. The lifting slings must be fully under the machine. Precondition The lifting frame complies with local safety regulations. 67

78 12 Decommissioning, Storage and Transport 12.5 Disposal Fig. 32 Transporting with a crane CAUTION The machine can be damaged by incorrect attachment of the lifting gear. Do not attach the lifting gear to any of the machine components. The manufacturer can advise on the use of suitable lifting gear. Use the lifting gear correctly and lift the machine carefully Disposal When disposing of a machine, drain out all liquids and remove dirty filters. Precondition The machine is decommissioned. 1. Completely drain the oil from the machine. 2. Remove old filters. 3. Hand the machine over to an authorized disposal expert. Components contaminated with oil must be disposed of in accordance with local environment protection regulations. 68

79 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 69

80 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 70

81 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 71

82 13 Annex 13.2 Dimensional Drawing 13.2 Dimensional Drawing 72

83 13 Annex 13.2 Dimensional Drawing 73

84 13 Annex 13.2 Dimensional Drawing 74