Related Manuals for KAESER EPC-G Series
Summary of Contents for KAESER EPC-G Series
- Page 1 Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com...
- Page 2 /KKW/PEPC 2.04 en SBA-KOLBEN-AGGREGAT 1-STUFIG 20170303 120254...
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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 ..........................Mass ..........................Compressor block ...................... - Page 4 Contents 4.2.2 Silenced air filter ....................4.2.3 Air filter with plastic casing .................. 4.2.4 Castors ....................... 4.2.5 Screwable rubber pads for air receiver mounting ..........4.2.6 Screwable rubber pads ..................Operating modes and control modes ................4.3.1 Machine operating modes .................. 4.3.2 External control unit ....................
- Page 5 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 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 De-commissioning ......................
- Page 6 Contents Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E...
- Page 7 List of Illustrations Fig. 1 Location of safety signs ......................Fig. 2 Machine overview ........................Fig. 3 Option C5: Oil level monitoring ....................Fig. 4 Option H9: Silenced air filter ....................... Fig. 5 Option H10: Air filter with plastic casing ..................Fig.
- Page 8 List of Illustrations Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E...
- 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 Mass ............................Tab. 6 Compressor block ........................Tab.
- Page 10 List of Tables Assembly and operating manual 1-stage piston compressor viii EPC-G No.: 9_5752 24 E...
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Page 11: Regarding This Document Using This Document
➤ Make sure you provide 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 Example: 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 here the nameplate data as a reference: Feature Value Reciprocating compressor Material no. Serial no. Year of manufacture Maximum working pressure Free air delivery Electrical connection... -
Page 15: Compressor Block
Technical Specifications Compressor block Compressor model Mass [kg] EPC 440-G 50/100 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. 5 Mass Compressor block Compressor block model Compressor model Number of cylinders Flow rate at 6 bar [l/min]... -
Page 16: Pressure
Technical Specifications Pressure Compressor model Inlet aperture (Z) [m Exhaust fan (A) EPC 440-G EPC 630-G EPC 840-G 1200 EPC 1100-G 1650 EPC 1500-G 0.75 2250 Forced ventilation: Required air volume for exhaust fan at static compression 1 mbar (machine in enclosed space without ducts and ΔT≙10 K) Tab. -
Page 17: Motor Power And Speed
Technical Specifications Motor power and speed Compressor model Sound pressure level [dB(A)] EPC 1500-G 80/74 Machine with sound enclosure Noise pressure level in operation at maximum working gauge pressure as per ISO 2151 and the basic standard ISO 9614-2, Operation at maximum working pressure, uncertainty: ±3 dB(A) Tab. -
Page 18: Compressor Oil Charge
Technical Specifications 2.11 Electrical connection ➤ Mark the oil that your compressor contains in the table below. Standard oil Special oil EPC 340/ EPC 630 – EPC 440 EPC 1500 Oil type SAE 5 W30 VDL 150 Application Standard oil for all ap‐ Standard oil for all ap‐... -
Page 19: Tab. 16 Supply Details 230V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection The connection to an IT three-phase supply or a three-phase supply with one earthed phase is not permitted. Further information When connecting to a European 400V/3/50Hz rated voltage the requirements in chapter 2.12 are also to be observed. 2.11.1.1 Power supply specifications The following supply cable conductor cross sections and fusing (slow-blow class gG) are selected... -
Page 20: Tab. 17 Supply Details 400V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection Rated voltage: 400V / 3 / 50Hz Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 340-G ● 4 x 1.5 4 x 1.5 440-G ●... -
Page 21: Tab. 19 Supply Details 690V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 1500-G 10.4 ● 4 x 1.5 – – ● Pressure switch ○ controller (START CONTROL) Tab. -
Page 22: Electrical Connection Data For Oil Level Monitoring
Technical Specifications 2.11 Electrical connection Rated voltage: 440V±10% / 3 / 60Hz Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 340-G ● 4 x 1.5 – – 440-G ●... -
Page 23: Mains Conditions
Technical Specifications 2.12 Mains conditions 2.12 Mains conditions The mains conditions apply to machines connected to public mains supplies with the following characteristics: ■ Mains frequency: 50 Hz ■ Voltage between external and neutral lines 220 V...250 V ■ Voltage between the external lines 380 V...430 V They do not apply to private power supplies within industrial areas isolated from the public mains. -
Page 24: Tab. 26 Machine Duty Cycle
Technical Specifications 2.13 Machine duty cycle The following values are valid for: ■ Ambient temperature 20 °C ■ 30 % relative humidity ■ 1013 mbar air pressure Compressor model Permissible duty cycle [%] Cycle time [min] EPC 340-G ≤ 70 3–30 EPC 440-G ≤... -
Page 25: 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 26: 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 27: Dangers
Safety and Responsibility Dangers Examples of German operation DGUV Regel 100 – 500 , chapter 2.11: ➤ Carry out recurring inspections to 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. Dangers Basic instructions Information concerning the various forms of danger that can arise during heat exchanger operation... - Page 28 Safety and Responsibility Dangers Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐ clude health and life-threatening dangers. ➤ Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and/or for the processing of foodstuffs.
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Page 29: Safe Machine Operation
➤ 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 Unsuitable spare parts compromise the safety of the machine. - Page 30 Safety and Responsibility Dangers ➤ Use suitable lifting gear that conforms to local safety regulations. ➤ Allow transportation only by personnel trained in the safe movement of loads. ➤ Attach lifting gear only to suitable lifting points. ➤ Be aware of the centre of gravity to avoid tipping. ➤...
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Page 31: Organisational Measures
➤ 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,... -
Page 32: Safety Devices
Safety and Responsibility Safety devices Activity Danger area Authorised personnel Operation Within a 1 m radius of the machine. Operating personnel Maintenance Within the machine. Maintenance personnel Within a 1 m radius of the machine. Tab. 27 Danger Areas Safety devices Various safety devices ensure safe working with the machine. -
Page 33: Information Signs
Safety and Responsibility Information signs Item Sign Meaning Hot surface! 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 Information signs The table lists the various information signs used and their meanings. -
Page 34: Injury From Handling Compressor Oil
Safety and Responsibility 3.11 Warranty Extinguishing substances ➤ Suitable extinguishing media: Foam Carbon dioxide Sand or soil ➤ Unsuitable extinguishing media: Strong jet of water 3.10.2 Injury from handling compressor oil Eye contact: Compressor oil can cause irritation. ➤ Rinse open eyes thoroughly for a few minutes under running water. ➤... -
Page 35: Environment Protection
Safety and Responsibility 3.12 Environment protection 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. 3.12 Environment protection The operation of this machine may cause dangers for the environment. -
Page 36: Design And Function
Design and Function Outline of the machine 4 Design and Function Outline of the machine 4.1.1 Machine structure Fig. 2 Machine overview Air filter Arrow showing direction of rotation Compressor block Compressed air outlet One cylinder Air pipe* Two cylinders Air cooler* Compressor motor Fan with cowl*... -
Page 37: Options
Design and Function Options Options The options available for your machine are described below. 4.2.1 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. -
Page 38: Castors
Design and Function Options Fig. 5 Option H10: Air filter with plastic casing Air filter cartridge 4.2.4 Option H14 Castors For moving the machine easily. Only in combination with a sound enclosure. Fig. 6 Option H14: Castors Castors Wheel stops 4.2.5 Option H20 Screwable rubber pads for air receiver mounting... -
Page 39: Screwable Rubber Pads
The control unit is not provided with the machine and is to be supplied by the user. WARNING Controller voltage! ➤ Incorrect control voltage can lead to irreparable damage to the electrical componentes. Use the START CONTROL controller by KAESER. The following points have to be observed: ■ Install the control unit to EN 60204 specifications. -
Page 40: Safety Devices
Design and Function Safety devices Safety devices The following safety devices are provided and may not be modified in any way. ■ Pressure relief valve: The pressure relief valve protects the system against excessive pressure. It is factory set. ■ Housing and covers for moving parts and electrical connections: Protect against accidental contact. -
Page 41: Accessories
Design and Function Accessories 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 6.10. Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G... -
Page 42: Installation And Operating Conditions
The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be kept to. Precondition The floor must be level, firm and capable of bearing the mass of the machine. -
Page 43: Ensuring The Machine Room Ventilation
It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine 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. -
Page 44: 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 Operating the machine 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 45: 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 46: 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 danger of tilting because of the high centre of gravity and mass of the machine. ➤... -
Page 47: Connecting The Machine With The Compressed Air Network
➤ Install only corrosion-resistant pipes. ➤ Use fluoroelastomers as sealing material for seals. ➤ Note the electro-chemical voltage sequence. ➤ Consult with KAESER for suitable materials for the compressed air network. Precondition The compressed air system is vented completely to atmospheric pressure. -
Page 48: Installation Examples
Installation Installation examples Fig. 13 Install the venting valve on-site Venting valve on the pressure switch Venting valve (solenoid valve) at the compressed air discharge point 1. DANGER! Dangerous voltage! There is danger of fatal injury caused by contact with live components. ➤... -
Page 49: Fig. 14 Typical Installation Of Safety And Regulating Devices
Installation Installation examples Fig. 14 Typical installation of safety and regulating devices Air receiver Pressure gauge Pressure switch Shut-off valve compressed air outlet Check valve Shut-off valve compressed air inlet Flexible pressurised hose to the machine Shut-off valve condensate drain Pressure relief valve Nozzle (machine-dependent) Test flange... -
Page 50: Two Machines With One Air Receiver
Installation Connecting the machine to the power supply 6.7.2 Two machines with one air receiver Fig. 15 Typical installation of two machines with one air receiver Air receiver Test flange Pressure switch Pressure gauge Check valve Shut-off valve compressed air outlet Machine Shut-off valve compressed air inlet Flexible pressurised hose to the machine... -
Page 51: Options
Installation Options 2. Carry out safety measures as stipulated in relevant regulations (e.g. IEC 364 or DIN VDE 0100) and in applicable national accident prevention regulations (BGV A3 in Germa‐ ny). In addition, observe the regulations of the local electricity supplier. 3. -
Page 52: Fig. 16 Option C5: Oil Level Monitoring
Installation Options Fig. 16 Option C5: Oil level monitoring Compressor block Oil level monitoring The contact in the oil level monitor is wired at the factory as a normally open contact. Oil level Electrical contact rises closes falls opens Tab. 30 Option C5: Oil level monitoring factory setting ➤... -
Page 53: Fig. 17 Option C5: Changing The Oil Level Monitoring Setting
Installation Options 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. ■... -
Page 54: Mounting The Machine On An Air Receiver
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.9.2 Option H20 Mounting the machine on an air receiver Fig. 18 Option H20: Screwable rubber pads Screwable rubber pad Threaded connection Model A Hexagon bolt Model B Hexagonal nut ➤ Use appropriate fixing elements to anchor the machine. Further information Details of the anchoring threads are shown in the dimensional drawing in chapter 13.2. -
Page 55: Dismantling The Sound Enclosure
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.10.1 Dismantling the sound enclosure Note how the parts fit together. ➤ Dismantle the sound enclosure 6.10.2 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 56: Fig. 20 Exchanging The Base Plate Of The Compressor Block In An Epc 340-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Exchanging the base plate of the compressor block Fig. 20 Exchanging the base plate of the compressor block in an EPC 340-G Base plate, compressor block Before modification After modification ➤ Detach the compressor block from the base plate, place the block on the newly provided base plate and fasten with the screws. -
Page 57: Fig. 21 Fitting The Epc 340 Sound Enclosure
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 21 Fitting the EPC 340 sound enclosure Rubber pad Fan with cowl Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Rubber pad Sound enclosure Base plate Air inlet louver Compressor block Removable panel Serrated locknut... -
Page 58: Fig. 22 Replacing The Compressor Block's Base Plate And Modifying The Air Filter, Epc 440-G
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.10.2.2 EPC 440-G Material Supplied base plate Supplied additional components for air filter Replacing the compressor block's base plate and modifying the air filter Fig. 22 Replacing the compressor block's base plate and modifying the air filter, EPC 440-G Base plate, compressor block Before modification Air filter... -
Page 59: Fig. 23 Fitting The Epc 440 Sound Enclosure
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 23 Fitting the EPC 440 sound enclosure Rubber pad Fan with cowl Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Rubber pad Sound enclosure Base plate Air inlet louver Compressor block Removable panel Serrated locknut... -
Page 60: Fig. 24 Modifying The Air Filter, Epc 630-G / Epc 840-G
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.10.2.3 EPC 630–G / EPC 840–G Material Supplied additional components for air filter Modifying the air filter Fig. 24 Modifying the air filter, EPC 630–G / EPC 840–G Air filter Before modification Angle After modification 1. -
Page 61: Fig. 25 Installing The Sound Enclosure, Epc 630-G / Epc 840-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 25 Installing the sound enclosure, EPC 630–G / EPC 840–G Rubber pad Sheet metal collar Rubber pad Compressed air cooler Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Spacer Sound enclosure Base plate Air inlet louver... -
Page 62: Fig. 26 Modifying The Air Filter, Epc 1100-G / Epc 1500-G
Installation 6.10 Retrofitting the sound enclosure (accessory) 8. Attach the sound enclosure to the base plate. 9. Screw the inlet air inlet louvre to the enclosure, hang the panel (exhaust louvre) in the enclo‐ sure and secure it with the snap fasteners. 6.10.2.4 EPC 1100–G / EPC 1500–G Material... -
Page 63: Fig. 27 Installing The Sound Enclosure, Epc 1100-G / Epc 1500-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 27 Installing the sound enclosure, EPC 1100–G / EPC 1500–G Rubber pad Sheet metal collar Rubber pad Compressed air cooler Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Spacer Sound enclosure Base plate Air inlet louver... - Page 64 Installation 6.10 Retrofitting the sound enclosure (accessory) 8. Attach the sound enclosure to the base plate. 9. Screw the inlet air inlet louvre to the enclosure, hang the panel (exhaust louvre) in the enclo‐ sure and secure it with the snap fasteners. Assembly and operating manual 1-stage piston compressor EPC-G...
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Page 65: 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 66: 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 authorised KAESER SERVICE technician. Tab. 31... -
Page 67: Motor Protection
1. Switch the machine on from the external control unit. The machine is shut down by the motor overload protection switch? ➤ Contact authorised KAESER SERVICE. Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E... -
Page 68: Checking The Direction Of Rotation
Initial Start-up Checking the direction of rotation Checking the direction of rotation The machine is designed for three-phase connection with right phase rotation. Ideally, the direction of phase rotation should be measured with a phase sequence meter. Alterna‐ tively, start the machine very briefly and observe the direction of rotation of the motor cooling fan. 1. -
Page 69: Operation
Operation Switching on and off 8 Operation 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 on the external controller. The following starting modes are available: ■... -
Page 70: Direct Online Start With Solenoid Valve
Operation 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. 8.1.2 Direct online start with solenoid valve Precondition... - Page 71 Operation Switching on and off Switching off 1. Switch off the machine via the external controller. 2. Switch off and lock out the power supply isolating device. Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G...
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Page 72: 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 73 Have the valve or valve plate cylinder head and cylinder are replaced by a leaking or dirty. KAESER SERVICE technician. Broken pressure valve reed. Call KAESER SERVICE. Motor overload protection trips Fault in the power supply. Check power supply.
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Page 74: Tab. 34 Faults And Remedies
Fault Recognition and Rectification Faults Fault Possible cause Remedy Air leaks from the user's pres‐ Defective switch diaphragm. Call KAESER SERVICE. sure switch while the machine The venting valve is not clos‐ Maintain or replace the unload‐ is running. ing. ing valve. -
Page 75: 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 76: Following The Maintenance Plan
Following the maintenance plan 10.2 Following the maintenance plan 10.2.1 Logging 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.: ■... -
Page 77: Regular Service Tasks
Maintenance 10.3 Maintaining the air cooler or fan cowl 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 fu‐ ture reference. -
Page 78: Cleaning The Air Cooler Or Fan Cowl
➤ Dry brush the air cooler or fan cowl and safety screen using a vacuum cleaner to suck up 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 The air filter contains a filter element that can be washed but not removed. -
Page 79: Air Filter (Sound Damping) Maintenance
Maintenance 10.5 Air filter (sound damping) maintenance Fig. 30 Air filter maintenance Air filter Retaining clip Inlet air opening Cover Filter element 1. Unscrew the air filter from the cylinder head. 2. Release the retaining clip and take off the cover. 3. -
Page 80: Air Filter (Plastic Housing) Maintenance
Maintenance 10.6 Air filter (plastic housing) maintenance 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 (<5 bar!) to blow dirt from the air filter cartridge at a slant from the in‐ side to the outside. -
Page 81: Drive Motor Maintenance
10.7 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. 10.8 Checking the oil level The oil level can be read off on the oil sight glass. -
Page 82: Changing The Compressor Oil
Maintenance 10.10 Changing the compressor oil 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 14. Fig. -
Page 83: Check The Pressure Relief Valve
The compressor oil has become milky white? It is contaminated with condensate. ➤ Change the oil immediately. ➤ Contact immediately KAESER SERVICE if condensate is detected in the oil. 10.11 Check the pressure relief valve ➤ To test the pressure relief valve, it must be removed from the machine by a KAESER SERVICE technician and installed on a test rig. -
Page 84: Venting The Machine (De-Pressurising)
2. Turn the knurled knob on the pressure relief valve anticlockwise until air blows off. 3. 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. 10.12 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. -
Page 85: Solenoid Valve Maintenance
Maintenance 10.13 Solenoid valve maintenance 1. DANGER! Compressed air! ➤ Compressed air and devices under pressure can injure or cause death if the contained en‐ ergy 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. -
Page 86: Cleaning The Solenoid Valve
Maintenance 10.13 Solenoid valve maintenance 10.13.1 Cleaning the solenoid valve Fig. 37 Cleaning the solenoid valve Solenoid valve Piston Screw Housing Coil Connecting socket Armature Arrow showing flow direction Spring 1. Remove the connecting socket from the solenoid valve. 2. Undo the screw and carefully remove the coil. 3. -
Page 87: Replacing The Solenoid Valve
Maintenance 10.14 Cylinder head and valves 10.13.2 Replacing the solenoid valve Fig. 38 Replacing the solenoid valve Solenoid valve Damper Screw connection Connecting socket 1. Remove the connecting socket from the solenoid valve. 2. Unscrew the defective solenoid valve wit damper from double nipple. 3. -
Page 88: Cleaning The Cylinder Head And Valves
2. Switch on the machine. 3. Switch off the machine and check for leaks. Significant malfunction in cylinder head and valves? Severe coking ➤ Have a KAESER SERVICE technician replace the cylinder head and valves. Assembly and operating manual 1-stage piston compressor EPC-G... -
Page 89: 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. 39 Logged maintenance tasks Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G... -
Page 90: 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 products. They are specifically se‐ lected for use in KAESER machines. WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuita‐... -
Page 91: Kaeser Air Service
■ 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 92: 12.1 Decommissioning, Storage And Transport
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 an au‐ thorized KAESER SERVICE technician for more information. Material... -
Page 93: 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 94: Disposal
Decommissioning, Storage and Transport 12.5 Disposal ➤ Please consult with KAESER if you have questions to the appropriate lifting gear. Precondition The lifting gear complies with local safety regulations. Fig. 41 Transporting with a crane 1. CAUTION! The machine can be damaged by incorrect attachment of the lifting gear! ➤... -
Page 95: 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) Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G... - Page 96 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E...
- Page 97 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G...
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Page 98: Dimensional Drawing
Annex 13.2 Dimensional Drawing 13.2 Dimensional Drawing Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E... - Page 99 Annex 13.2 Dimensional Drawing Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G...
- Page 100 Annex 13.2 Dimensional Drawing Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E...
- Page 101 Annex 13.2 Dimensional Drawing Assembly and operating manual 1-stage piston compressor No.: 9_5752 24 E EPC-G...
- Page 102 Annex 13.2 Dimensional Drawing Assembly and operating manual 1-stage piston compressor EPC-G No.: 9_5752 24 E...