Summary of Contents for KAESER KCT blue T Series
- Page 1 Operator manual Reciprocating compressor KCT blue T No.: 902350 00E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 www.kaeser.com...
- Page 2 Original instructions /KKW/PDENT 2.10 en SBA-DENTAL-T-ANLAGE 20190503 092636...
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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 ........................Options ..........................Weight ..........................Compressor block ...................... - Page 4 Contents Accessories ........................4.4.1 Sound enclosure ....................Installation and Operating Conditions Ensuring safety ........................ Installation conditions ....................... 5.2.1 Determining location and clearances ..............5.2.2 Ensuring the machine room ventilation ............... 5.2.3 Prevention of thermal problems ................5.2.4 Operation in a compressed air network .............. Installation Ensuring safety ........................
- Page 5 Contents Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Ordering replacement parts ..................... 11.3 KAESER AIR SERVICE ....................11.4 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 De-commissioning ......................12.2 Packing ..........................12.3 Storage ..........................
- Page 6 Contents Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
- Page 7 List of Illustrations Fig. 1 Location of safety signs ......................Fig. 2 Machine layout ........................... Fig. 3 Compressed air drying ....................... Fig. 4 Recommended machine placement and dimensions [mm] ............Fig. 5 Fitting the rubber pads ....................... Fig. 6 Air connection ..........................Fig.
- Page 8 List of Illustrations Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
- Page 9 List of Tables Tab. 1 Danger levels and their definition (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options ............................Tab. 5 Weight ............................Tab. 6 Compressor block ........................Tab.
- Page 10 List of Tables Operator manual Reciprocating compressor viii KCT blue T No.: 902350 00E...
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Page 11: Regarding This Document Using This Document
➤ Make sure you give the data from the nameplate when ordering documents. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. Symbols and labels ➤... -
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 machine's nameplate provides the model designation and important technical information. ➤ Enter here the nameplate data as a reference: Characteristic Value Reciprocating compressor Material No. Serial No. Year of manufacture Maximum working pressure Flow rate Electrical connection Synchronous speed... -
Page 15: Compressor Block
Technical Specifications Compressor block Compressor block The flow rate depends on the final pressure relating to the intake conditions (pressure and temper‐ ature). Flow rate: The amount of compressed air delivered by the compressor per time unit, measured e. g. in l/min Compressor type Compressor Usable flow rate... -
Page 16: Pressure Switch Setting
Technical Specifications Pressure switch setting Pressure switch setting Specified pressures are factory set. Customer-specific settings may differ. Characteristic Value Cut-in pressure [bar] Cut-out pressure [bar] Maximum pressure differential [bar] Pressure, air receiver [bar] KCT blue 230-65 T The air receiver is permanently in a pressure fluctuation range of 20%. Tab. -
Page 17: Motor Power And Speed
Technical Specifications 2.10 Motor power and speed 2.10 Motor power and speed ➤ Read off the motor protection class from the motor nameplate and enter in the table: AC version Compressor type Compres‐ Rated power [kW] Synchronous rated Protection sor block speed [rpm] class 50 Hz... -
Page 18: Alternating Current
Technical Specifications 2.11 Electrical connection 2.11.1 Alternating current The machine requires an alternating current power supply. The machine may only be operated from an earthed alternating current supply network. Further information When connecting to a European 230V/1/50Hz rated voltage power supply network you must also observe the requirements in chapter 2.12. -
Page 19: Three-Phase Power Supply
Technical Specifications 2.11 Electrical connection Rated voltage: 115V / 1 / 60Hz Compressor type Backup fuse [A] Rated current, motor Supply line [mm KCT blue 110-24 T 3 x 1.5 Tab. 15 Connection data 115V / 1 / 60Hz Rated voltage: 208–230V / 1 / 60Hz Compressor type Backup fuse [A] Rated current, motor... -
Page 20: Network Conditions
Technical Specifications 2.12 Network Conditions ➤ For other application conditions, check and determine the supply cross-sections accord‐ ing to DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider. Other application conditions would include, for example: ■ Higher ambient temperature ■... -
Page 21: Supply Conditions At 400V / 3 / 50Hz
The data are relative to the sum of impedances in external and neutral lines. Tab. 19 Network impedance 2.13 Tightening torques for screws/ nuts For tightening torques, please contact an authorised KAESER SERVICE technician. Operator manual Reciprocating compressor No.: 902350 00E KCT blue T... -
Page 22: 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 23: User's Responsibilities
Safety and Responsibility User's responsibilities ➤ Do not allow the machine to take in toxic, acidic, flammable or explosive gases or vapours. ➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force. User's responsibilities 3.4.1 Observe statutory and universally accepted regulations... -
Page 24: Dangers
Inspection authority Installation and equip‐ Before commissioning if Qualified persons ment inspection PS x V ≤ 200 (e. g. KAESER SERVICE techni‐ cian) Compressors with type approval Competent person (Ordinance on Industrial Safety and (e. g. KAESER SERVICE techni‐ Health, annex 5 no. 25) cian) PS x V ≤... - Page 25 Safety and Responsibility Dangers Electricity Touching voltage-carrying components can result in electric shocks, burns or even death. ➤ 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‐ trical engineering rules.
- Page 26 Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only original KAESER spare parts on pressure bearing parts. Conversion or modification of the machine Modifications, additions or conversions to or of the machine can result in unpredictable hazards.
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Page 27: Safe Machine Operation
Safety and Responsibility Dangers ➤ When extending or modifying the compressed air station: Check the blow-off capacity of safety valves on air receivers and in compressed air lines be‐ fore installing a new machine. ➤ If the blow-off capacity is insufficient: Install safety valves with higher blow-off capacity. - Page 28 ➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: for visible damages,...
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Page 29: Organisational Measures
Safety and Responsibility Safety devices This machine is oil-free! ➤ Do not pour oil into the crankcase. De-commissioning, storage and disposal: ➤ Dispose of the machine in accordance with local environmental regulations. 3.5.3 Organisational Measures ➤ Designate personnel and their responsibilities. ➤... -
Page 30: Fig. 1 Location Of Safety Signs
Safety and Responsibility Safety signs Fig. 1 Location of safety signs Location Symbol Meaning Danger of fatal injury from electric shock! ➤ Before starting any work on electrical equipment: Switch off and lock out the power supply isolating device and verify the absence of any voltage. -
Page 31: Emergencies
Safety and Responsibility Emergencies Location Symbol Meaning Follow instructions in the operating manual ➤ Read and understand the operating manual before working on the ma‐ chine. ➤ Do not attempt tasks other than those described in this manual. Isolate the power supply isolating device from all power phases. ➤... -
Page 32: 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. 3.10 Environment protection ➤ Store and dispose of replaced parts in accordance with local environment protection regula‐... -
Page 33: Design And Function
Design and Function Machine overview 4 Design and Function Machine overview 4.1.1 Machine Machine layout Fig. 2 Machine layout Air filter housing Compressed air cooler Compressor block Condensate outlet Check valve Compressed air outlet Air receiver Pneumatic venting valve Safety valve Timer module Pressure switch Solenoid valve... -
Page 34: Compressed Air Dryer
Design and Function Machine overview Machine function For compression, atmospheric air is cleaned by the air filter and drawn into the compression cham‐ ber of the compressor block. The air is drawn in during the downward stroke of the piston. It is compressed during the upward stroke. -
Page 35: Operating Points And Control Modes
Design and Function Operating points and control modes Desiccant regeneration phase As soon as the machine switches on, the timer modules starts at start period T1. The compressor delivers dried air to the receiver until the expiry of time period T1. At the end of period T1, the desiccant is regenerated for a period of 15 seconds: Warm compressed air passes through the desiccant and removes the absorbed moisture. -
Page 36: Safety Devices
Design and Function Safety devices ■ Pressure switch: According to the set switching points, the pressure switch toggles the machine between the op‐ erating modes LOAD and READY. ■ Timer module: The timer regulates regeneration phases of the compressed air dryer. It toggles the compres‐ sor between LOAD and IDLE. -
Page 37: Installation And Operating Conditions
The clearances given are recommended and ensure unhindered access to all machine parts. ➤ Please consult KAESER if they cannot be adhered to. Precondition The floor must be level, firm and capable of bearing the weight of the machine. -
Page 38: Ensuring The Machine Room Ventilation
It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult KAESER if you cannot ensure the conditions for adequate ventilation of the ma‐ chine room. 1. Ensure that the flow rate of fresh air is at least the same as the flow rate taken by the machine and exhaust fan from the machine room. -
Page 39: Prevention Of Thermal Problems
Ensure that hot exhaust air leaves the room by the shortest direct path. ■ Do not exceed the permissible duty cycle. ➤ KAESER can offer advice in this respect. 5.2.4 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 final pressure of the machine. -
Page 40: 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! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 41: Reporting Transport Damage
Installation Reporting Transport Damage 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. Fitting the rubber pads CAUTION There is a risk of tipping because of the high centre of gravity and mass of the machine. ➤... -
Page 42: Connecting The Machine To The Power Supply
Installation Connecting the machine to the power supply 1. WARNING! Serious injury or death can result from loosening or opening components under pressure! ➤ Fully de-pressurise all pressurised components and enclosures. 2. A shut-off valve must be installed by the user in the connection line. 3. -
Page 43: Dismantling The Sound Enclosure
Installation Sound enclosure retrofit 6.6.1 Dismantling the sound enclosure Note how the parts fit together. ➤ Undo the fixing screws and dismantle the sound enclosure. 6.6.2 Fitting the sound enclosure Prior to any work requiring the opening of the pressure system, the machine must be fully iso‐ lated from the compressed air network and completely depressurised. - Page 44 Installation Sound enclosure retrofit 1. DANGER! Electric voltage! Risk of fatal injury caused by contact with live components! ➤ Switch off and lock out the power supply isolating device and check that no voltage is present. 2. WARNING! Compressed air! Compressed air and devices under pressure can cause serious injury or cause death if the contained energy is released suddenly.
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Page 45: Initial Start-Up Ensuring Safety
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 46: Instructions To Be Observed Before Any Commissioning
Remedy than: 36 months ➤ Have the overall technical condition checked by an authorised KAESER SERVICE technician. Tab. 23 Re-commissioning after storage Checking installation and operating conditions ➤ Check and confirm all the items of the checklist before commissioning the machine:... -
Page 47: Resetting The Motor Overload Protection Switch For Single-Phase Motors
Initial Start-up Checking direction of rotation (3-phase machines only) The overload protection cut-out setting can be higher than the rated motor current to prevent it from being triggered by voltage fluctuations, temperature influences or component toleran‐ ces. 1. Read the rated motor current from the nameplate and calculate the correct protection setting. 2. -
Page 48: Starting The Machine For The First Time
Initial Start-up Starting the machine for the first time Fig. 9 Checking the direction of rotation CEE plug Phase 2 and 3 ➤ If the direction of rotation is wrong, disconnect the machine from the power supply network. ➤ Reverse phases L2 and L3. Starting the machine for the first time Precondition No personnel are working on the machine. -
Page 49: Operation
Operation Switching on and off 8 Operation Switching on and off Always switch the machine on and off with the «ON/OFF» switch. A power supply isolating device has been installed by the user. Symbol Meaning Start Start Turn the «ON/OFF» switch to the “I” position. Auto The compressor is controlled automatically by the pressure switch. -
Page 50: Operating Hours Counter
Operation Operating hours counter Switching on 1. WARNING! Compressed air! Risk of serious injury. ➤ Never direct compressed air at persons or animals. ➤ Make sure that no one is working on the machine. 2. Switch on the power supply isolating device. 3. -
Page 51: 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 representative. Faults Fault... -
Page 52: Tab. 26 Faults And Troubleshooting
Call KAESER SERVICE. der head. loose. Replace gasket. Gasket defective. The safety valve blows off be‐ Pressure switch incorrectly set. Call KAESER SERVICE. fore the cut-out pressure is Valve spring defective. Replace the safety valve. reached. Dirt or foreign bodies on the Let the safety valve blow off valve seat. -
Page 53: 10.1 Maintenance
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 54: Maintenance Schedule
Maintenance schedule 10.2 Maintenance schedule 10.2.1 Document maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■ high temperatures ■... -
Page 55: Maintaining The Air Cooler Or Fan Cowl
Maintenance 10.3 Maintaining the air cooler or fan cowl ➤ Service work should be carried out in a timely manner, taking local ambient and operating con‐ ditions into account: Interval Maintenance task Up to 10000 h, Have the compressed air dryer cooling checked. at the latest every 5 years Up to 3,000 h, every two Check reed valves, and replace as necessary. -
Page 56: Cleaning The Air Cooler Or Fan Cowl
➤ Dry brush the air cooler or fan cowl and safety screen and use a vacuum cleaner to remove the dirt. The air cooler or fan cowl can't be cleaned thoroughly? ➤ Have severe clogging removed by an authorised KAESER SERVICE technician. 10.4 Air filter maintenance All sealing surfaces have been designed to match each other. -
Page 57: Filter Mat Maintenance
3. Replace the cover and screw down. 10.6 Drive motor maintenance The drive motor bearings are permanently greased. Re-greasing is not necessary. ➤ Have the motor bearings checked by an authorised KAESER Service. 10.7 Checking the pressure relief valve Precondition Machine switched off while under LOAD (air receiver at maximum pressure). -
Page 58: Air Receiver Maintenance
3. 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. Further information See chapter 2.8 for the activating pressure of the valve. 10.8... -
Page 59: Maintaining The Check Valve
Shut-off valve still open. ➤ Close the shut-off valve. ➤ If manual venting does not attain de-pressurisation: Contact the authorised KAESER SERVICE. 10.10 Maintaining the check valve The check valve is installed in the air receiver inlet port. It prevents the compressed air from flow‐... -
Page 60: Cylinder Head And Valves
3. Clean the valve seat and valve cone with a cleaning cloth and blow out with dry compressed air (<2 bar!). The check valve must be replaced by the authorised KAESER SERVICE technician if the valve seat shows severe wear or is damaged. -
Page 61: Documenting Maintenance And Service Work
Maintenance 10.12 Documenting maintenance and service work 10.12 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. 29 Logged maintenance tasks Operator manual Reciprocating compressor No.: 902350 00E KCT blue T... -
Page 62: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering replacement parts KAESER replacement parts are original products. They are specifically selected for use in KAES‐ ER machines. WARNING Personal injury or damage from the use of unsuitable consumables! Unsuitable or poor quality replacement parts may damage the machine or severely impair its proper function. -
Page 63: Replacement Parts For Service And Repair
■ The security of genuine KAESER spares. ■ Increased legal certainty as all regulations are kept to. ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed air availability. 11.4 Replacement parts for service and repair ➤... -
Page 64: 12.1 Decommissioning, Storage And Transport
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 65: Transport
Weight and centre of gravity determine the most suitable method of transportation. The centre of gravity is shown in the drawing in chapter 13.2. Please consult with KAESER if you intend to transport the machine in freezing temperatures. Precondition Transport only by fork truck and only one operated by personnel trained in the safe movement of goods. -
Page 66: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor KCT blue T No.: 902350 00E... - Page 67 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor No.: 902350 00E KCT blue T...
- Page 68 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
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Page 69: Dimensional Drawing
Annex 13.2 Dimensional drawing 13.2 Dimensional drawing Operator manual Reciprocating compressor No.: 902350 00E KCT blue T... - Page 70 Annex 13.2 Dimensional drawing Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
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Page 80: Electrical Diagram
Annex 13.3 Electrical diagram 13.3 Electrical diagram 13.3.1 Electrical diagram 1 of 3 Operator manual Reciprocating compressor KCT blue T No.: 902350 00E... - Page 81 Annex 13.3 Electrical diagram Operator manual Reciprocating compressor No.: 902350 00E KCT blue T...
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Page 87: Electrical Diagram 2 Of 3
Annex 13.3 Electrical diagram 13.3.2 Electrical diagram 2 of 3 Operator manual Reciprocating compressor No.: 902350 00E KCT blue T... - Page 88 Annex 13.3 Electrical diagram Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
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Page 95: Electrical Diagram 3 Of 3
Annex 13.3 Electrical diagram 13.3.3 Electrical diagram 3 of 3 Operator manual Reciprocating compressor No.: 902350 00E KCT blue T... - Page 96 Annex 13.3 Electrical diagram Operator manual Reciprocating compressor KCT blue T No.: 902350 00E...
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