KAESER AIRTOWER 3C Operator's Manual
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KAESER AIRTOWER 3C Operator's Manual

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Operator Manual
Screw Compressor
AIRTOWER 3C–7.5C
9_6917 34 USE
manroland-document-no.:
80.95A EN F254
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Tri-Voltage

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Summary of Contents for KAESER AIRTOWER 3C

  • Page 1 Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE manroland-document-no.: 80.95A EN F254 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 Original instructions /KKW/SSXC 2.14 en Z1 SBA-SCHRAUBEN-TRI-VOLTAGE-AC-SCB 20160524 092822...

  • Page 3: Table Of Contents

    Pressure ........................... Air receiver ........................Free air delivery (FAD) ..................... 2.10 Cooling Oil Recommendation ..................2.10.1 Basic Information ....................2.10.2 KAESER Lubricants .................... 2.11 Cooling oil charge ......................2.12 Motor and performance ....................2.12.1 Compressor motor ....................2.13 Sound emission ........................
  • Page 4 Switching off in an emergency and switching on again ............ Setting parameters ......................Acknowledging alarm and warning messages ..............Fault Recognition and Rectification Basic instructions ......................Fault messages (machine shut down) ................Warning messages ......................Other faults ........................Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 5 10.19 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 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 Decommissioning ......................
  • Page 6 Contents Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 7 Checking the condensate drain ....................Fig. 33 Changing the service unit ......................Fig. 34 Air receiver maintenance ......................Fig. 35 Transporting with a forklift truck ....................Fig. 36 Transporting with a crane ......................Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 8 List of Illustrations Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 9 Oil change intervals lubricants ....................Tab. 43 Regular service tasks ......................... Tab. 44 Permissible cooling oil level under LOAD ................. Tab. 45 Logged maintenance tasks ......................Tab. 46 Consumable parts ........................Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 10 List of Tables Operator Manual Screw Compressor viii AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • 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

    ➤ The protective measures against the damages are shown here. ➤ Carefully read and fully comply with warnings against damages. 1.4.3 Other alerts and their symbols This symbol identifies particularly important information. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 13 The cause is named in the help text ... ➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment. Further information Further subjects are introduced here. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 14: Technical Data Nameplate

    Power supply of Dryer Voltage Phase Package FLA Refr. compr. FLA Characteristic Value Wiring Diagram FOR SERVICE, REFER TO EQUIPMENT NUMBER Tab. 3 Nameplate Options The table contains a list of possible options. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 15: Weight

    ✓ not available: — Tab. 4 Options Weight The values shown are maximum values. Actual weight of individual machine is dependent on equipment fitted. AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C Weight [lb] Tab. 5 Weight Temperature AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C...

  • Page 16: Ventilation

    Technical Data Ventilation AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C Cooling air tempera‐ 40 – 115 40 – 115 40 – 115 40 – 115 ture [°F] Intake air temperature 40 – 115 40 – 115 40 – 115 40 –...

  • Page 17: Air Receiver

    Technical Data Air receiver Safety relief valve activating pressure [psi] Maximum working pres‐ AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER sure [psig] 7.5C — Tab. 9 Safety relief valve activating pressure Air receiver Volume AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C...

  • Page 18: Basic Information

    Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐ pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire-resistant fluid.

  • Page 19: Cooling Oil Charge

    USDA H-1approved and NSF certified. FG-460 is approved for canning, food packing, meat and poultry processing and other applications where incidental food contact may occur. 2.11 Cooling oil charge AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C Total charge [qt.] Topping off volume [qt.]...

  • Page 20: Sound Emission

    Three-phase star (wye); 4 wire; grounded neutral Fig. 3 Three-phase star (wye); 3 wire; grounded neutral Further information Please contact an authorized KAESER service representative for options. The electrical diagram 13.3 contains further specifications for electrical connection. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 21: Power Supply Specifications

    Table 250.122 will point out the ”minimum size”, however, we recommend a ground conductor the same size as the power leads, if local codes allow. Rated power supply 208V ±10%, 3-ph, 60Hz AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C...

  • Page 22: Refrigerated Dryer

    2.16 Refrigerated dryer 2.16 Refrigerated dryer Model AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 5C Model * * Read off the dryer model from the dryer nameplate and enter it in the table. Tab. 20 Refrigerated dryer: Model Compressed air system...

  • Page 23: Power Supply Specifications

    13.3 if a common power supply is provided. Rated power supply: 115V / 1 / 60Hz CT 4 CT 8 Pre-fuse [A] Supply 3xAWG14 3xAWG14 Consumption [A] Tab. 23 Power supply 115V / 1 / 60Hz Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 24: Safety And Responsibility Basic Instructions

    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. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 25: Qualified Personnel

    Warning instructions are found before a potentially dangerous task. 3.5.1 Safely dealing with sources of danger The following describes the various forms of danger that can occur during machine operation. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 26 Springs under tension or compression are a contained force. Uncontrolled release of this force can cause serious injury or death. Minimum pressure / check valves, safety relief valves and inlet valves are powerfully spring-loaded. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 27 Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts for pressure components. Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredict‐...

  • Page 28: Safe Machine Operation

    ➤ Never dismantle compressed air pipes until they are fully vented. ➤ Only use pressure lines that are suitable and approved for the maximum working pressure and the intended medium. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 29 ➤ 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 30: Organizational Measures

    ➤ 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 chapter 4, section 4.5. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 31: Working Life Of Safety Functions

    ■ Main contactor 1. The functions of the safety components must be replaced by an authorized KAESER service representative after a working life of 20 years. 2. Have an authorized KAESER service representative check the reliability of the safety func‐...
  • Page 32 Serious injury or death can result from loosening or opening component that is un‐ der pressure and heavily spring loaded! ➤ Do not open or dismantle the valve. ➤ Call for authorized KAESER Service representative if a fault occurs. Serious injury or death can result from loosening or opening component under pressure! ➤...

  • Page 33: Emergency Situations

    ➤ Seek medical help if irritation persists. Skin contact Cooling oil may irritate after prolonged contact. ➤ Wash thoroughly with skin cleaner, then with soap and water. ➤ Contaminated clothing should be dry-cleaned before reuse. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 34: Injury From Handling Refrigerant

    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, ■ unauthorized modifications, Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 35: Environmental Protection

    ■ 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. 3.11 Environmental protection The operation of this machine may cause dangers for the environment.

  • Page 36: Design And Function

    (A) then lifting off (B). Replacing the canopy Replace the canopy in the reverse order from removal, making sure the bracket engages in the guides. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 37: Machine Function

    Compressed air is cooled in the receiver and chilled in the refrigeration dryer . Most of the mois‐ ture carried in the air is removed in this way. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 38: Refrigerated Dryer

    The safety relief valve protects the system against excessive pressure. It is factory set. ■ Resistance thermometer: Monitoring the airend discharge temperature protects the compressed air system from imper‐ missible temperature rises. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 39: Floating Relay Contacts

    Resets the maintenance interval counter. «Down» Scrolls down the parameter list. Reduces a parameter value. «Up» Scrolls up the parameter list. Increases a parameter value. «Cancel» Exits the edit mode without saving. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 40: Functional Description - Sigma Control Basic

    . x b a r Line 2 ° C Line 3 0 0 0 0 Line 4 1 2 3 4 5 6 7 8 S p T i Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 41: Parameter

    Parameter Meaning Operating hours counter Displays the total time the drive motor was switched on. Only an authorized KAESER service representative has the right to change this pa‐ rameter. Maintenance interval counter Displays the number of operating hours until the next scheduled maintenance is due.

  • Page 42: Messages

    Fan: switching differential The difference between cut-in and cut-out temperatures is the fan switching differen‐ tial. Only an authorized KAESER service representative has the right to change this pa‐ rameter. Fan: switching point The switching point determines the fan cut-in temperature.

  • Page 43: Operating Modes And Control Modes

    In this mode the refrigerated dryer runs continuously, even if the compressor is not running. The refrigerated dryer is switched off together with the compressor. 4.11 Options The options available for your machine are described below. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 44: Machine Mountings

    Design and Function 4.11 Options 4.11.1 Option H1 Machine mountings These mountings allow the machine to be anchored firmly to the floor. Fig. 10 Machine mountings Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 45: 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 46: 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 flow volume of fresh air is at least the same as the volume taken by the ma‐...

  • Page 47: Operating The Machine In A Compressed Air System

    These conditions are detrimental to correct air treatment. Air quality suffers. To en‐ sure the desired air quality when charging a vented air system, we recommend the installation of an air main charging system. ➤ Consult an authorized KAESER service representative for advice on this subject. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 48: Installation

    ➤ Do not open the cabinet while the machine is switched on. Further information Details of authorized personnel are found in chapter 3.4.2. Details of dangers and their avoidance are found in chapter 3.5. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 49: Reporting Transport Damage

    ➤ 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 50: Tab. 30 Condensate Line

    Max. length [ft] Max. delivery head [ft] Material Copper (pressure-resistant, cor‐ Stainless steel rosion-proof) Plastics Hose line For longer lengths, please contact KAESER before installation. Tab. 30 Condensate line Condensate collecting line Feature Value Gradient [%] >1 Max. length [ft]...

  • Page 51: Refrigerated Dryer: Connecting The Transformer According To The Power Supply

    The electrical diagram in chapter 13.3 contains further details of the power supply connection. Making the Power Supply Connection The machine is not wired ready for operation! This is a Tri-Voltage machine. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 52: Changing Main Voltage Connections

    Transformer for the refrigerated dryer (only if present). Material The required jumpers (also known as ’bridges’ or ’links’) are provided in the control cabinet. Precondition A check has been made to ensure no voltage is present. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 53: Options

    Changing the drive motor connection ➤ Open the control cabinet and connect the motor in accordance with the electrical diagram. Adjusting the overload protection cutout ➤ Check the overload protection relay setting. AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7.5C 208V, 3-ph, 60Hz [A] 12.2...

  • Page 54: Initial Start-Up Ensuring Safety

    ➤ Do not open the cabinet while the machine is switched on. Further information Details of authorized personnel are found in chapter 3.4.2. Details of dangers and their avoidance are found in chapter 3.5. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 55: Instructions To Be Observed Before Commissioning Or Re-Commissioning

    ➤ Change the oil filter. ➤ Change the oil separator cartridge. ➤ Change the cooling oil. ➤ Have the motor bearings checked by an authorized KAESER service repre‐ sentative. 36 months ➤ Have the overall technical condition checked by an authorized KAESER service representative.

  • Page 56: Setting The Overload Protection Relay

    ➤ Check the overload protection relay setting. The overload protection relay shuts the machine down despite being correctly set? ➤ Contact an authorized KAESER service representative. Pouring cooling oil into the airend Before starting the compressor for the very first time and before re-starting after a shutdown period of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend.

  • Page 57: Starting The Machine For The First Time

    System setpoint pressure: Switching differential This switching differential is factory set. Adjust this parameter if the motor starting frequency is too high. Precondition The machine has been running at least 5 minutes under LOAD. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 58 3. 2. Press and hold «enter» for at least 3 seconds until the cursor flashes. 3. Use the arrow keys to set the desired differential and confirm with «Enter». Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 59: Operation

    2. Switch off and lock out the power supply disconnecting device. The machine is switched off and isolated from the power supply. The Controller Power LED extinguishes. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 60: Switching Off In An Emergency And Switching On Again

    1. Scroll with the «UP»/«DOWN» keys until the desired parameter appears in line 3. 2. Depress the «enter» key for at least 3 seconds. Result Depending on the parameter, either the displayed value or the first character of the required pass‐ word flashes. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 61: Acknowledging Alarm And Warning Messages

    Alarm LED (red) «Acknowledge» key Alarm message Messages are displayed on the "new value" principle: ■ Message received: LED flashes ■ Message acknowledged: LED lights ■ Message gone: LED extinguished Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 62 ■ Message coming: LED flashes ■ Message gone: LED extinguished ➤ Rectify fault or carry out maintenance. Warning LED extinguishes as soon as the cause of the warning is rectified. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 63: Fault Recognition And Rectification

    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 authorized KAESER service representative. Fault messages (machine shut down) The fault code appears in the 4th line of the display field.

  • Page 64: Warning Messages

    Machine below minimum permissi‐ ➤ Increase room temperature. ble starting temperature. Safety relief valve check mode ➤ Check safety relief valve. switched on. ➤ Deactivate check mode. Tab. 38 Warning messages Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 65: Other Faults

    Other faults Other faults Fault Possible cause Remedy Machine runs but produces no Inlet valve not opening or only Call an authorized KAESER compressed air. opening partially. service representative. Venting valve not closing. Call an authorized KAESER service representative. Leaks in the pressure system.

  • Page 66: 10 Maintenance

    0 psig. ➤ Do not open or dismantle any valves. When working on the drive system Touching voltage-carrying components can result in electric shocks, burns, or death. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 67: Following The Maintenance Plan

    3. When the cursor flashes, confirm the offered value with the «Enter» key. 10.2.3 Regular maintenance tasks The table below lists maintenance tasks required. The refrigeration circuit is hermetically sealed. Repairs may only be carried out by certified person‐ nel. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 68: Cooling Oil Changing Interval

    Machine utilization and ambient conditions are important criteria for the number and length of the change intervals. An authorized KAESER service representative will support you in determining appropriate in‐ tervals and provide information on the possibilities of oil analysis. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 69: Regular Service Tasks

    Oil change intervals lubricants 10.2.5 Regular service tasks The table below lists necessary service tasks. ➤ Have an authorized KAESER service representative carry out service tasks. ➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐ count. Interval...

  • Page 70: Cooler Maintenance

    Face mask (as required) Precondition The power 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. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 71: Air Filter Maintenance

    ➤ Have stubborn clogging removed by an authorized KAESER service representative. Checking the cooler for leaks ➤ Carry out visual inspection: Can oil be seen escaping? Is the cooler leaking? ➤ Have the defective cooler repaired immediately by an authorized KAESER service repre‐ sentative. 10.5 Air Filter Maintenance Check that all sealing surfaces match each other.

  • Page 72: Compressor Motor Maintenance

    4. Clip the air filter housing onto the inlet valve. 10.6 Compressor motor maintenance The drive motor bearings are permanently greased. Re-greasing is not necessary. ➤ Have the motor bearings checked by an authorized KAESER service representative. 10.7 Maintaining the drive belt Material...

  • Page 73: Checking The Cooling Oil Level

    The sightglass allows a risk-free reading of the cooling oil level. The oil indicator should be fully filled with oil when the machine is at standstill. The correct oil level cannot be seen. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 74: Venting The Machine (Depressurizing)

    The maintenance hose with hose coupling and shut-off valve needed for venting is lying on the ma‐ chine. Precondition The power supply disconnecting device is switched off, The device is locked off, A check has been made that no voltage is present. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 75: Fig. 23 Venting The Machine

    ➤ Disconnect the male hose fitting and close the shut-off valve ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact an authorized KAESER service representative. Operator Manual Screw Compressor 9_6917 34 USE...

  • Page 76: Replenishing Cooling Oil

    3. Disconnect the male hose fitting and close the shut-off valve The air receiver pressure gauge does not read 0 psig after venting? ➤ Contact an authorized KAESER service representative. Result The machine is fully depressurized when both pressure gauges show 0 psig after manual venting.

  • Page 77: Venting The Machine (Depressurizing)

    3. Disconnect the male hose fitting and close the shut-off valve The air receiver pressure gauge does not read 0 psig after venting? ➤ Contact an authorized KAESER service representative. Result The machine is fully depressurized when both pressure gauges show 0 psig after manual venting.

  • Page 78: Topping Off With Cooling Oil And Carrying Out A Trial Run

    The maintenance hose with hose coupling and shut-off valve is stowed inside the machine. There is risk of burns from hot components and oil! ➤ Wear long-sleeved clothing and protective gloves. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 79: Fig. 25 Changing The Cooling Oil, Oil Separator Tank

    Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drain) Cooling oil level indicator Shut-off valve (control line) Male hose fitting Shut-off valve (oil drain) Shut-off valve Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 80 Draining the oil from the separator tank Contact an authorized KAESER service representative if condensate is detected in the cool‐ ing oil. It is necessary to adapt the airend discharge temperature to individual ambient conditions.

  • Page 81: Changing The Oil Filter

    The machine is fully vented, the pressure gauge on the oil separator tank reads 0 psig. There is risk of burns from hot components and oil! ➤ Wear long-sleeved clothing and protective gloves. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 82: Changing The Oil Separator Cartridge

    The life of the oil separator cartridge is influenced by: ■ Contamination in the air drawn into the compressor, ■ Adherence to the changing intervals for: ─ Cooling oil ─ Oil filter ─ Air filter Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 83: Fig. 27 Changing The Oil Separator Cartridge

    3. Switch on the power supply and reset the maintenance interval counter. 4. Start the machine and run it for 10 minutes, then stop it and visually check for leaks. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 84: Checking The Safety Relief Valve Activating Pressure

    ➤ Safety relief valves on machines with maximum permissible working pressure of 215 psig should be tested only by an authorized KAESER service representative. Blowoff protection and air system pressure monitoring are switched off during the test.

  • Page 85: Checking The Air Receiver Relief Valve

    ➤ Make sure that the enclosure cover is in place. ➤ Wear ear and eye protection. ➤ Abort the test if the working pressure rises 10% above the activating pressure of the valve. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 86: Returning The Machine To Operational

    Check the safety shut-down due to excessive airend discharge temperature. The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F. ➤ Have the safety shutdown function checked by an authorized KAESER service representative. 10.16 Testing the EMERGENCY STOP push button Fig.

  • Page 87: Maintaining The Refrigerated Dryer

    1. Brush dirt from the refrigerant condenser and vacuum up. 2. Blow out as required with compressed air (<72 psig). The refrigerant condenser can no longer be cleaned? ➤ Have stubborn clogging removed by an authorized KAESER service representative. Operator Manual Screw Compressor 9_6917 34 USE...

  • Page 88: Maintaining The Condensate Drain

    The condensate drain cannot be cleaned. The service unit must be changed if condensate does not drain. Material Sealing tape for sealing the screw-in part If required: O-ring 16x2 (5.1519.0) Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 89: Fig. 33 Changing The Service Unit

    7. Remove the insulation from the service unit. Installing the service unit Use only genuine KAESER service units to ensure correct function of the condensate drain. Precondition Make sure the top of the service unit and the contact spring are clean and dry.

  • Page 90: Air Receiver Maintenance

    User's shut-off valve between the machine and the air network is closed. The machine is completely vented to atmospheric pressure, i.e. both pressure gauges (see Fig 23) are showing 0 psig. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 91 All condensate is drained when only compressed air is blown out. 4. Close the shut-off valve and unplug the male hose fitting. Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...

  • Page 92: Documenting Maintenance And Service Work

    Documenting maintenance and service work Equipment number: ➤ Enter maintenance and service work carried out in the checklist below. Date Maintenance task carried out Operating hours Signature Tab. 45 Logged maintenance tasks Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 93: 11 Spares, Operating Materials, Service

    11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original KAESER products. They are spe‐ cifically selected for use in KAESER machines. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐...

  • Page 94: Service Addresses

    11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Replacement parts for service and repair Use these parts lists to plan your material requirement according to operating conditions and to or‐...
  • Page 95 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 96 Spares, Operating Materials, Service 11.5 Replacement parts for service and repair Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 97: 12 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 representative for more information. Material...

  • Page 98: Transport

    Weight and center of gravity determine the most suitable method of transportation. The center of gravity is shown in the drawing in chapter 13.2. ➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐ tures.

  • Page 99: Disposal

    ■ Rain protection covers ➤ Please consult with KAESER if you have questions to the appropriate lifting gear. Precondition The lifting gear complies with local safety regulations. No pressure should bear on the sides of the enclosure.
  • Page 100 Decommissioning, Storage and Transport 12.5 Disposal Compressors with refrigeration dryers The refrigerant circuit still contains both refrigerant and oil. ➤ Refrigerant and oil must be drained and disposed of by authorized personnel. Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 101: 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 Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 102 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 103 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 104 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 105 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 106 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 107: Dimensional Drawing

    Annex 13.2 Dimensional Drawing 13.2 Dimensional Drawing Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 108 Annex 13.2 Dimensional Drawing Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

  • Page 109: Electrical Diagram

    Annex 13.3 Electrical Diagram 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 110 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 111 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 112 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 113 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 114 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 115 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 116 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 117 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 118 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 119 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 120 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 121 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 122 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...
  • Page 123 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 9_6917 34 USE AIRTOWER 3C–7.5C Tri-Voltage...
  • Page 124 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor AIRTOWER 3C–7.5C Tri-Voltage 9_6917 34 USE...

This manual is also suitable for:

Airtower 4cAirtower 5cAirtower 7.5c

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