Related Manuals for KAESER Premium Compact W 200/4
Summary of Contents for KAESER Premium Compact W 200/4
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Page 1: Reciprocating Compressor
Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E Manufacturer: KAESER KOMPRESSOREN 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com... - Page 2 Original instructions /KKW/PPWCO 2.00 en SBA-PREMIUM COMPACT-TRAGBAR 20120822 115136...
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Page 3: Table Of Contents
Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Specifications Nameplate ........................Weight ..........................Compressor block ......................Ambient conditions ...................... - Page 4 10.15 Documenting maintenance and service work ..............Spares, Operating Materials, Service 11.1 Note the Nameplate ......................11.2 Ordering consumable parts and operating fluids/materials ..........11.3 KAESER AIR SERVICE ....................11.4 Service Addresses ......................11.5 Spares for service and repair ................... Decommissioning, Storage and Transport 12.1 Decommissioning ......................
- Page 5 Contents 12.3 Storage ..........................12.4 Transporting ........................12.4.1 Safety ........................12.5 Disposal ........................... Annex 13.1 Dimensional Drawing ....................... 13.2 Electrical Diagram ......................Service Manual Reciprocating compressor No.: 9_9418 20E Premium compact W...
- Page 6 Contents Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E...
- Page 7 List of Illustrations Fig. 1 Location of safety signs ......................Fig. 2 Machine layout ........................... Fig. 3 Compressed air connection ......................Fig. 4 Motor overload protection switch ....................Fig. 5 Setting the network pressure ...................... Fig. 6 Setting the pressure regulator ....................Fig.
- Page 8 List of Illustrations Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E...
- Page 9 List of Tables Tab. 1 Danger levels and their definitions (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Weight ............................Tab. 5 Compressor block ........................Tab. 6 Ambient conditions ........................Tab.
- Page 10 List of Tables Service Manual Reciprocating compressor viii Premium compact W No.: 9_9418 20E...
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Page 11: Regarding This Document Using This Document
Copyright This service manual is copyright protected. Queries regarding use or duplication of the documenta‐ tion should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document. -
Page 12: Potential Damage Warnings
Regarding this document Symbols and labels DANGER These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur. - Page 13 Regarding this document Symbols and labels Material Here you will find details on special tools, operating materials or spare parts. Precondition 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 ➤...
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Page 14: Technical Specifications Nameplate
Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine's nameplate. ➤ Enter the data from the nameplate here as a reference. Feature Value Reciprocating compressor Article No. Serial No. Year of manufacture Maximum working pressure Inlet volume Rated voltage... -
Page 15: Ambient Conditions
Technical Specifications Ambient conditions Ambient conditions Installation Maximum altitude 1000 amsl* [m] Permissible ambient tem‐ 5–35 perature [°C] * Higher altitudes are permissible only after consultation with the manufacturer. Tab. 6 Ambient conditions Pressure switch setting Specified pressures are factory set. Customer-specific settings may differ. -
Page 16: Motor Power And Speed
Technical Specifications Motor power and speed Emission sound pressure level ■ calculated from the measured average sound power level (directive 2000/14/EG, Sound Meas‐ uring Standard ISO 3744) according to EN ISO 11203:1995 6.2.3d at distance d = 1 m, Q2 = Logarithmic surface ratio: dB. EC type approval: ■... -
Page 17: Compressor Oil Charge
Technical Specifications 2.10 Power Supply ➤ Mark the oil that your compressor contains in the table below. Standard oil Special oil Oil type SAE 5 W30 Field of application Standard oil for all applications Specifically for machines in ap‐ except in connection with food‐ plications where the com‐... -
Page 18: Tab. 14 Mains Supply 110V/1/50Hz
Technical Specifications 2.10 Power Supply 2.10.1.1 Power supply specifications The following conductor cross-sections (copper multicore) and fusing (industrial fuses, slow blow) are given according to VDE 0100, parts 430 and 523 (IEC 60364–4–43) for ambient temperatures from 30 °C and laying method C. ➤... -
Page 19: Mains Conditions
Technical Specifications 2.11 Mains conditions Rated power supply: 115V±5%/1/60Hz Premium compact Mains fusing [A] Current consumption Supply cable [mm 160/4 — — — 200/4 — — — 250/4 3 x 4 15.6 Tab. 17 Mains supply 115V/1/60Hz Rated power supply: 127V±5%/1/60Hz Premium compact Mains fusing [A] Current consumption... -
Page 20: Mains Conditions At 230V/1/50Hz
Technical Specifications 2.12 Machine duty cycle No interference with other devices is to be expected with network impedance less than Z [Ohm]. In general, the maximum permissible network impedance will not be exceeded if the ma‐ chine is supplied at the transfer point with a rated current of I equiv 2.11.1 Mains conditions at 230V/1/50Hz... -
Page 21: Safety And Responsibility Basic Instructions
Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■... -
Page 22: User's Responsibilities
Safety and Responsibility User's Responsibilities User's Responsibilities 3.4.1 Observe statutory and universally accepted regulations. This is, for example, nationally applied European directives and/or valid national legislation, safety and accident prevention regulations. ➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐ nance of the machine. -
Page 23: Dangers
Inspecting authority Installation and equip‐ Before commissioning if pressure Competent person ment inspection PS x volume V ≤ 200 (e. g. KAESER Service Techni‐ cian) Compressors with type approval in‐ Competent person spection (Ordinance on Industrial (e. g. KAESER Service Techni‐... -
Page 24: Safely Dealing With Sources Of Danger
Safety and Responsibility Dangers 3.5.1 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 elec‐... -
Page 25: Safe Machine Operation
➤ 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 ➤... - Page 26 Safety and Responsibility Dangers 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 load tipping over. ➤...
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Page 27: Organisational Measures
Safety and Responsibility Safety Devices Maintenance ➤ Make sure the machine is disconnected from electrical power and vented before commencing any work. ➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary. ➤ Do not leave any loose components, tools or cleaning rags on or in the machine. Decommissioning, storage, disposal ➤... -
Page 28: Information Signs
Safety and Responsibility Information signs Fig. 1 Location of safety signs Item Sign Meaning Danger of fatal injury from electric shock! ➤ Before beginning any work on electrical equipment: Switch off the mains disconnecting device, lock it in the off position and check that the machine is free of voltage. -
Page 29: In Emergency
Safety and Responsibility In emergency Sign Meaning Maintain the air filter regularly. Drain the condensate daily. If automatic condensate drainage is fitted, check the function at regular intervals. Check the oil level regularly and change the oil at the correct intervals. Tab. -
Page 30: Warranty
■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11 Environment protection The operation of this machine may cause dangers for the environment. -
Page 31: Design And Function
Design and Function Machine function 4 Design and Function Machine function Fig. 2 Machine layout Air filter Oil drain plug Compressor block Compressed air connection Check valve Condensate drain tap Air receiver Pressure regulator Air receiver pressure relief valve Working pressure gauge Pressure switch Fan with cowl Electric motor... -
Page 32: Operating Modes And Control Modes
Design and Function Operating modes and control modes Operating modes and control modes 4.2.1 Operating modes There are two operating modes: ■ LOAD: The compressor block delivers compressed air. The drive motor runs under full load. ■ STANDSTILL: No air is compressed. A check valve prevents compressed air flowing back into the compres‐ sor block. -
Page 33: Installation And Operating Conditions
Installation and Operating Conditions Ensuring safety 5 Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 34: Installation
Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 35: Compressed Air Connection
Installation Compressed air connection Compressed air connection Precondition The machine is isolated from the air consumers. Fig. 3 Compressed air connection Compressed air connection ➤ Make the connection to the air main by a flexible pressure line. Connecting the machine to the power supply Machines with a total power rating up to 3 kW and rated current up to 16 amps may be plugged into the mains supply. -
Page 36: Initial Start-Up Ensuring Safety
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 37: Instructions To Be Observed Before Commissioning Or Re-Commissioning
Storage period Remedy longer than: 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. 26... -
Page 38: Resetting The Motor Overload Protection Switch For Single-Phase Motors
Initial Start-up Measuring the air receiver charging time 7.4.1 Resetting the motor overload protection switch for single-phase motors Single phase motors are fitted with a thermal overload protection switch that is set to a fixed value. It ensures shutdown of the machine at levels of current above the value set on the motor overload protection. -
Page 39: Fig. 5 Setting The Network Pressure
Initial Start-up Setting the network pressure Fig. 5 Setting the network pressure Canopy «ON/OFF» switch for direct online start Screw Premium compact 160/4 Adjusting screw for upper pressure (cut- Premium compact 200/4 / 250/4 / 300/4 out) Pressure differential adjusting screw 1. -
Page 40: Setting The Pressure Regulator
Initial Start-up Setting the pressure regulator Adjusting the setting Function The pressure differential between cut-in and cut- ➤ Turn the adjusting screw anticlockwise (in out pressure is to be decreased. the - direction). Tab. 29 Changing the pressure switch setting 6. -
Page 41: Operation
Operation Switching on and off 8 Operation Switching on and off Always switch the machine on and off with the ON/OFF switch. The «ON/OFF» switch is located on the pressure switch. Precondition A power supply disconnecting device has been installed by the user. The plastic canopy is in place. -
Page 42: Fault Recognition And Rectification
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. In all other cases, have the fault rectified by an authorised KAESER Service Technician. Alarms Alarm... -
Page 43: Tab. 30 Alarms And Remedies
The machine runs continuously Air filter clogged. Maintain or replace the air filter. but maximum pressure is not Valves* or valve plate between Contact KAESER Service. reached. cylinder head and cylinder are leaking or dirty. Outlet valve reed broken. Contact KAESER Service. -
Page 44: 10 Maintenance
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 45: Maintenance Schedule
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 32 for fu‐... -
Page 46: Regular Service Tasks
10.2.4 Regular service tasks ➤ Only an authorized KAESER Service Technician should carry out service work. ➤ 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 inter‐... -
Page 47: Air Filter Maintenance
Maintenance 10.4 Air filter maintenance The fan cowl can't be cleaned thoroughly? ➤ Have stubborn clogging removed by an authorized KAESER Service Technician. 10.4 Air filter maintenance The air filter insert consists of foam. Replace the air filter if it has already been cleaned a number of times. -
Page 48: Checking The Oil Level
Maintenance 10.6 Checking the oil level 10.6 Checking the oil level The oil level can be read off on the oil sight glass. Precondition The machine is switched off. Fig. 10 Checking the oil level Oil sight glass Oil filler and crankcase vent ➤... -
Page 49: Changing The Compressor Oil
Change the initial charge of oil as specified in table 31 . Always drain the oil completely from the compressor block. 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 Compressor oil Oil receptacle Precondition Machine at operating temperature. -
Page 50: Pressure Relief Valve Checking
4. Switch off the machine and check visually for leaks. 10.9 Pressure relief valve checking ➤ To test the pressure relief valve, it must be removed from the machine by a KAESER Service Technician and installed on a test rig. Further information Details about the activating pressure of the pressure relief valve are found in chapter 2.6. -
Page 51: Air Receiver Maintenance
5. Open the user's shut-off valve between the machine and the air distribution network. Result The machine can now be started. Pressure relief valve does not blow off? ➤ Have the defective relief valve replaced by KAESER Service. 10.10 Air receiver maintenance Material... -
Page 52: Venting The Machine (De-Pressurising)
Maintenance 10.11 Venting the machine (de-pressurising) Fig. 14 Draining condensate Condensate drain tap ➤ Drain the condensate out daily. Drain the condensate into a suitable receptacle and dispose of according to environmental regulations. 10.11 Venting the machine (de-pressurising) Even when switched off the machine is still under pressure from the air network back to the check valve. -
Page 53: Maintaining The Check Valve
Shut-off valve still open. ➤ Defective condensate drain. ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER Service. 10.12 Maintaining the check valve The check valve is installed in the air receiver inlet port. It prevents the compressed air from flow‐... -
Page 54: Maintenance Of The Pressure Switch Unloading Valve
Maintenance 10.13 Maintenance of the pressure switch unloading valve 10.13 Maintenance of the pressure switch unloading valve According to the pressure switch version, the relief valve can be cleaned or must be replaced. The unloading valve must be cleaned in the following circumstances: ■... -
Page 55: Cylinder Head And Valves
➤ Start the machine and measure the receiver charging time. Result If there is a significant difference in the charging time to when the machine was new, have KAESER Service check or replace the valves. Further information See chapter 7.5 for air receiver charging time measurement. -
Page 56: Documenting Maintenance And Service Work
Maintenance 10.15 Documenting maintenance and service work 10.15 Documenting 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. 34 Logged maintenance tasks Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E... -
Page 57: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are selec‐ ted for use in KAESER machines. WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuita‐... -
Page 58: Service Addresses
11.4 Service Addresses Addresses of KAESER agents are given at the end of this manual. 11.5 Spares for service and repair ➤ Make sure that any service or repair tasks not described in this manual are carried out by an authorised KAESER Service Technician. -
Page 59: 12.1 Decommissioning, Storage And Transport
Packing A wooden crate is required for overland transport to protect the machine from mechanical damage. Other measures must be taken for the transport of machines by sea or air. Please contact KAESER Service for more information. Material Desiccant Plastic sheeting... -
Page 60: Storage
Storage Moisture can lead to corrosion, particularly on the surfaces of the compressor block. Frozen moisture can damage components, valve diaphragms and gaskets. Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. NOTICE! Moisture and frost can damage the machine! ➤... -
Page 61: 13 Annex
Annex 13.1 Dimensional Drawing 13 Annex 13.1 Dimensional Drawing Service Manual Reciprocating compressor No.: 9_9418 20E Premium compact W... - Page 62 Annex 13.1 Dimensional Drawing Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E...
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Page 63: Electrical Diagram
Annex 13.2 Electrical Diagram 13.2 Electrical Diagram Service Manual Reciprocating compressor No.: 9_9418 20E Premium compact W... - Page 64 Annex 13.2 Electrical Diagram Service Manual Reciprocating compressor Premium compact W No.: 9_9418 20E...