Regarding this Document Regarding this Document Handling the Document The service manual is part of the machine. . Keep the service manual in a safe place throughout the life of the machine. . Pass the manual on to the next owner/user of the machine. .
Regarding this Document 1.4.2 Other notices and symbols This symbol indicates that a task is to be carried out. This symbol identifies environmental protection measures. This symbol refers to particularly important information. 1 --- 2...
Technical Specification Technical Specifications The model designation and important technical information are given on the machine’s nameplate. . Please enter the data from the nameplate here: Model Part no. Serial no. Year Initial press. Displ. Max. working pressure Voltage Hz/RPM Phase Package FLA Drive Motor FLA...
Technical Specification Maximum working pres- Pressure relief valve blow-- off setting [psig] sure [psig] 145 --- 650 Tab. 6 Venting line relief valve blowoff pressures Further data on pressure relief valves can be found in chapter 13.2. Sound Pressure Level Operational state: under LOAD at rated speed, rated air flow and rated pressure.
Technical Specification 2.7.2 Compressor: N 502 Nominal compressor --- 1 speed [min Tab. 11 Compressor specifications Oil Recommendations Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in compressor oils. These deposits block the flow of lubricant and cause excessive wear and failure of moving parts.
Technical Specification When switching from mineral oil to a synthetic oil, the plant’s system materials must be re–evaluated. Certain plastics are not compatible with synthetic oils. The following is a par- tial list of acceptable and not recommended materials: ACCEPTABLE NOT RECOMMENDED Viton Celcon...
Technical Specification 2.9.2 Power supply specifications The following multi–strand copper core wires are given according to 2005 NEC 310.15, Table 310.16 for 40 ˚C ambient temperature. If other local conditions prevail, like for example high temperature, the cross section should be checked and adjusted according to 2005 NEC 110.14E, 220.3, 310.15, Table 310.16, 430.6, 430.22, 430.24 and other local codes.
Technical Specification 2.10 Machine Duty Cycle The permissible duty cycle of the machine is related to the compression ratio (final pres- sure P absolute / inlet pressure P absolute), the ambient temperature and the com- pressed air inlet temperature. The maximum compression ratio is 4.5:1 Max.
Safety and Responsibility Safety and Responsibility Disregard of these instructions can result in serious injury. DANGER . Read the service manual carefully and take notice of the contents for safe machine operation. The machine is manufactured to the latest engineering safety standards and acknowl- edged safety regulations.
Safety and Responsibility User’s Responsibilities Observe statutory and accepted regulations. Observe relevant statutory and accepted regulations during installation, operation and maintenance of the machine. For example: nationally applied European directives and/or valid national legislation, safety and accident prevention regulations. 3.3.1 Qualified personnel Ensure that operating, installation and maintenance personnel are qualified and authorized to carry out their tasks.
Safety and Responsibility Dangers The general safety instructions in this chapter show possible dangers and how to deal with them. Special safety instructions are found in this service manual at the beginning of each chap- ter or directly before operating instructions. 3.4.1 Safely dealing with sources of danger Information concerning the various forms of danger that can arise in connection with ma-...
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Safety and Responsibility Rotating components Touching the fan while the machine is running can result in serious injury. . Do not open the enclosure or covers while the machine is running. . Isolate all phases of the main power supply. .
Safety and Responsibility 3.4.2 Safe machine operation Information on safe conduct when handling the machine is found here. Transport . Use suitable lifting gear that conforms to local safety regulations. . Attach lifting gear only to suitable lifting points on the machine. .
Safety and Responsibility Maintenance . Make sure the machine is disconnected from electrical power and vented before com- mencing any work. . Wear close–fitting, flame–resistant clothing. Wear protective clothing as necessary. . Do not leave any loose components, tools or cleaning rags on or in the machine. .
Safety and Responsibility Safety Signs The table lists the various safety signs used and their meanings. The diagram shows the positions of the signs on the machine. Position Sign Meaning Voltage Touching electrically live components can cause serious injury or death.
Safety and Responsibility Warranty This service manual contains no independent warranty commitment. Our general terms and conditions of business apply with regard to warranty. A condition of our warranty is that the machine is used for the purpose for which it is in- tended under the conditions specified.
Design and Function Design and Function Machine Overview 4.1.1 Primary components Fig. 2 Major Components Compressor block Drive motor Terminal box Compressed air aftercooler 4 --- 19...
Design and Function Inlet port; inlet from the low ---pressure network Compressed air outlet to the high ---pressure network Compressor block, compresses the inlet air [1] Collecting pipe, collects the incoming air and allows it to settle Aftercooler; collects the compressed air, allows it to settle and dissipates the heat of compression through the cooling fins [13] Check valve;...
Design and Function A pressure switch ensures that the compressor only runs within the permitted inlet pres- sure range. A filter is installed in the venting line. Controlled by a solenoid valve (open when de–ener- gized), accumulating liquid (condensate and dirt) is trapped in the filter bowl. A safety relief valve is installed to protect the filter.
Design and Function Safety Devices 4.3.1 Existing safety devices The following safety devices are provided and may not be modified: Safety relief valve The safety relief valve protects the system from excessive pressure. This is factory set. The housing and covers for moving parts and electrical connections. Protect against accidental contact.
Design and Function Check valve The sizing of the check valve is dependent on the maximum working pres- sure and the cross–section of the connection between the compressor and the air network. Install a check valve to prevent backflow of compressed air out of the network. Install the valve between the compressed air outlet and the user’s shut off valve.
Installation and Operating Conditions Installation and Operating Conditions Surroundings . Strictly forbid fire, open flame and smoking. . If welding is carried out on or near the machine, take adequate measures to prevent sparks or heat from igniting oil vapours or parts of the machine. .
Installation and Operating Conditions 5.2.2 Prevention of thermal problems Ensure adequate air inlet and outlet apertures in the room (see chapter 5.2.3). Correct location of the apertures (constant airflow). Correct machine positioning (all machines must be able to draw in cool fresh air). Hot exhaust air must leave the room by the shortest direct path.
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Installation and Operating Conditions Fig. 6 Installation recommendation, with other machines 5 --- 27...
Installation and Operating Conditions 5.2.3 Ventilation Values given are minimum guide values. If cooling air is insufficient a dangerous vacuum can build up in the com- pressor room. Make sure that cooling air flows around the machine. Ensure that the volume of air flowing into the compressor room is at least equivalent to that being removed by the exhaust fan.
Installation Installation Safety Dangerous voltage! DANGER There is danger of fatal injury caused by contact with live components. . Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) . Ensure that the power supply cannot be switched on again (locked off).
Installation Reporting Transport Damage . Check the machine for visible and hidden transport damage. . Inform the carrier and the manufacturer in writing of any damage found. Fitting Equalising Shims There is a danger of tipping because of a shift of the center of gravity and weight of the machine.
Installation Making the Compressed Air Connections Pre–condition: The compressed air system is at atmospheric pressure. Fig. 8 Schematic diagram of compressed air connections Low pressure network (73 --- 190 psig) High pressure network (up to 653 psig) Rotary screw compressor Air receiver Refrigeration dryer Microfilter combination...
Installation 6.4.1 Connection to the low–pressure system . Connecting to the low pressure system via a pipe connection. Pipe connection: Swan neck Fig. 9 Low pressure system connection Compressed air pipe Low pressure system Microfilter Hose Machine (low pressure compressed air inlet) A microfilter must be installed to ensure safe operation of the machine.
Installation 6.4.2 Connection to the high–pressure system . Connect the machine to the high–pressure system via a hose. Fig. 10 High pressure system connection Machine (low pressure compressed air inlet) Machine (high pressure compressed air outlet) Making the Power Supply Connection Main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC, OSHA, and any applicable local codes.
Installation Controller Design Use a controller designed to EN 60 204 for the connection to the power supply. The machine is fitted with a normally closed solenoid valve in the compressed air inlet and a normally open solenoid valve in the venting line. The following components are already wired in the terminal box fixed to the machine, see diagram in chapter 13.1.3.
Installation Inlet pressure switch System pressure switch Machine (fitted by the user) fitted by the user p > p < p < p starts up p > p p < p runs under LOAD p > p p = p switches to IDLE p >...
Installation 6.7.1 Dismantling the sound enclosure Note how the parts fit together. . Open the snap fasteners and dismantle the enclosure. 6.7.2 Fitting the sound enclosure Pre–condition: sufficient space around and above the machine, suitable lifting gear. Fig. 11 Screw together the rear panel Rear panel Machine mounting bracket Machine mounting...
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Installation Fig. 12 Fitting the sound enclosure Rear panel Control and instrument panel Side panel Exhaust air aperture for the axial extrac- tor fan Cover panel Door Front panel Snap fastener Terminal box . Use the copper pipe provided with the enclosure to connect the high–pressure gauge (final pressure p2) onto the compressed air cooler.
Initial Start-up Initial Start–Up Safety Dangerous voltage! DANGER Contact with live components can cause serious injury or death. . Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) . Ensure that the power supply cannot be switched on again (locked off).
Initial Start-up Checking Installation and Operational Conditions Check and confirm all the items in the checklist before starting the machine. Check that Chapter . Are all the installation conditions fulfilled? . User’s lockable supply disconnecting device installed? . Does the power supply conform to the specifications on the nameplate? .
Initial Start-up Setting the Overload Protection Cut–Out Three–phase motors may only be operated with a correctly set overload protection cut–out. Operating the machine without adequate overload protection is not permitted. Operating without overload protection invalidates the warranty. Drive motor: direct online starting The overload protection cut–out is to be installed in the user’s controller and set–up corre- spondingly.
Initial Start-up 7.6.1 Machine switching frequency from STANDSTILL to LOAD Limited adjustment of the switching frequency from STANDSTILL to LOAD is possible by adjusting the switching differential. This is achieved by adjusting the inlet pressure switch setting. See chapter 2.7.1 for maximum switching frequency from STANDSTILL to LOAD per hour.
Operation Operation Switching on and off with the external controller. Automatic restart DANGER Serious injury is possible. The machine restarts automatically when power returns after a power sup- ply failure. The machine starts automatically when pressure in the high–pressure net- work falls below cut–in pressure.
Event Recognition and Fault Rectification Fault Recognition and Rectification Inform authorized KAESER Service representative if the fault cannot be rectified by the ac- tion suggested. Do not attempt rectification measures other than those given in this manual. The alarm indications valid for your machine are dependant on the individual equipment. Fault Diagnosis Fault Possible cause...
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Event Recognition and Fault Rectification Fault Possible cause Remedy Machine runs hot. Ambient temperature too Reduce the ambient tem- high. perature. Inlet pressure too low. Check the inlet pressure switch. Compression ratio too high. Reduce the compression ratio. Wrong direction of rotation. Swap the L1 and L2 con- nections to the drive motor.
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Event Recognition and Fault Rectification Fault Possible cause Remedy Machine uses too much oil. Viscosity too low. Fill with oil specified in the service manual. Crankcase venting defec- Clean or renew the crank- tive. case vent. Piston rings worn or broken. Contact authorized KAESER Service represen- tative Filter in the venting line...
Maintenance Maintenance 10.1 Safety Any disregard of these instructions and/or incorrect handling may result in serious injuries. High Voltage! DANGER There is danger of fatal injury caused by touching electrically live compo- nents. . Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) .
Maintenance Maintenance work may only be carried out by authorised personnel! Before switching on again ensure that: no one is working on the machine, all panels are in place and secured, all access doors are closed. 10.2 Maintenance Schedule Maintenance intervals are recommendations only and should be adjusted to suit installation and operating conditions.
Maintenance 10.2.2 Oil change intervals The duty cycle and ambient conditions are important criteria for the number and length of the change intervals. RECOMMENDED KAESER LUBRICANTS SIGMA DESCRIPTION MAXIMUM RECOMMENDED LUBRICANT CHANGE INTERVAL* First Oil Change Subsequent Oil Change M---150 ISO 100 Semi---Synthetic 50 Hours 1,000 Hours...
Maintenance 10.2.3 Regular service work Only authorized KAESER Service representatives should carry out service work. When operating conditions are unfavourable (e. g. dusty atmosphere or high ambient temperature) or if the equipment is in constant use, service work must be carried out more frequently. Interval Regular service work See chapter...
Maintenance . Clean sealing faces. . Wet the filter insert (3) with a little oil after cleaning the air filter. If the insert is heavily contaminated, clean with a solvent–based fluid or wa- ter jet. Observe safety regulations. Replace the air filter if it has already been cleaned a number of times. Replacing the air filter .
Maintenance . Dry brush the cooler (1) and use a vacuum cleaner to suck up the dirt. 10.4.2 Checking for leaks Pre–condition: Machine switched off. Power supply disconnecting device locked out. The machine is cooled down. Pay especial attention to aging and corrosion of the cooler materials under long term oper- ating conditions.
Maintenance 10.6.2 Topping up the compressor oil Compressor oil Equipment: Pre–condition: Power supply disconnecting device is locked out. The machine is cooled down. Risk of explosion from the compressor oil. WARNING Fatal injuries can be caused by the ignition of oil mist and vapors. .
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Maintenance Dispose of the old oil in accordance with valid environmental protection regulations. Drain the oil completely from the compressor block. . Wear long–sleeved clothing and gloves. . Work with caution. Fig. 16 Changing the oil, compressor block Oil filler Oil drain plug Oil level sight glass The first charge of oil must be changed after about 1000 operating hours.
Maintenance . Remove the oil drain plug (2) and allow the oil to drain into the oil catchment container. . Screw in the oil drain plug again together with the ring seal. . Top up with new oil to the maximum mark on the oil sight glass. .
Maintenance The oil filter element must be changed after 2000 operating hours. . Unscrew the cap (3) from the crankcase vent (1). Escaping oil mist is damaging to health. CAUTION . Do not inhale oil mist and vapours. . Avoid contact with skin and eyes. .
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Maintenance Fig. 18 Changing the crankcase oil filter Oil filter Direction of rotation to unscrew the filter Change the oil filter for the first time after 1000 operating hours, along with the oil. A further oil filter change is necessary: after 2000 operating hours, or after every oil change, or if the oil pressure switch has shut down the machine because the oil pressure has...
Maintenance 10.10 Maintaining the Dirt Trap Compressed air for blowing out. Equipment: Cleaning agents Pre–condition: Machine switched off. Power supply disconnecting device locked out. The machine is cooled down. User’s inlet and outlet shut–off valves closed. 10.10.1 Dirt traps in the inlet and venting lines. Hot components -- danger of burns! Wear long–sleeved clothing.
Maintenance 10.10.2 Dirt trap in the crankcase. Hot components -- danger of burns! CAUTION Wear long–sleeved clothing. Work with caution. Fig. 20 Dirt trap in the crankcase Dirt trap Dirt trap strainer O–ring Screw plug Clean the dirt trap: if a fault occurs because of insufficient oil pressure, or annually.
Maintenance Clean the damper and sintered filter insert. . Blow out the damper with compressed air (< 70 psig). . Remove the retaining nut and the sintered filter insert. . Clean the insert and blow through from the inside to the outside. .
Maintenance If the maximum permissible working pressure at the discharge end is ex- ceeded the pressure relief valve (2) opens, blowing off excessive air to pro- tect the compressor and the air consumers. The machine may only be operated with a correctly functioning pressure relief valve.
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Maintenance Fig. 23 Cleaning the check valve Check valve Valve seat Screw plug Spring Valve cone O–ring Cleaning the check valve: . Remove the screw plug (2). . Clean the valve cone (3) and seat (4). Replace the valve cone (3), spring (5) and O–ring (6) if they are badly worn. Replace the check valve if the valve seat is damaged.
Maintenance 10.14 Replacing the Solenoid Valve Ingress of dirt during operation can prevent the valve from sealing. To ensure trouble–free operation, the solenoid valve should be replaced every 12,000 operating hours. Spare part Equipment: Pre–condition: Machine switched off. Power supply disconnecting device locked out. Machine fully vented to atmospheric (pressure gauge reads 0 psig).
Maintenance 10.15 V–belt Maintenance 10.15.1 Check the belts and their tension. Pre–condition: Machine switched off. Power supply disconnecting device locked out. Machine fully vented to atmospheric (pressure gauge reads 0 psig). The machine is cooled down. User’s inlet and outlet shut–off valves closed. 0.4”---0.8”...
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Maintenance Fig. 26 Tensioning the belts Hexagonal nut Square ---headed bolt . Loosen the hexagonal nuts on the motor mountings and the square–headed bolts in the tensioning rails. . Shift the motor until the belts are tensioned again, i.e. there is only 0.4”---0.8” move- ment.
Maintenance 10.15.2 Changing the V–belts Set of V–belts Equipment: Fig. 27 Changing the V–belts Air network connection Temperature gauge switch sensor Belt guard (external part) Bracket rail Fittings Bracket Air cooler . Remove the guard outer part (2). . Remove the fittings (3) from the air cooler (4). .
Maintenance Starting the machine and carrying out a trial run: . Open the user’s inlet and outlet shut–off valves. . Switch on the main power supply disconnecting device. . Switch on the machine. 10.16 Inspecting or Replacing the Cylinder Head and Valves The condition of the valves can be assessed by measuring the receiver charging time and comparing this with the charging time when the ma- chine was new.
Maintenance Starting the machine and carrying out a trial run: . Open the user’s inlet and outlet shut–off valves. . Switch on the main power supply disconnecting device. . Switch on the machine. . Switch off the machine and visually check for leaks. 10.17 Changing the Microfilter Element.
Spares, Operating Materials, Service Spares, Operating Materials, Service 11.1 Note the nameplate Make sure to quote the data on the nameplate for all enquiries and spare parts orders. 11.2 Ordering Consumable Parts and Operating Materials Personal injury or machine damage may result from the use of unsuit- able spare parts or operating materials.
Spares, Operating Materials, Service energy savings achieved by avoidance of pressure losses, optimum conditions for operation of the compressed air system, the security of genuine KAESER spare parts. increased legal certainty as all regulations are kept to. 11.4 Service Addresses Addresses of KAESER are given at the end of this manual.
Decommissioning, Storage and Transport Decommissioning, Storage and Transport 12.1 Decommissioning De---commissioning is necessary when the machine: will not be needed for some time, is to be moved to another location, is no longer needed, is to be scrapped. Temporarily decommissioning Pre–condition: The machine can be started at regular intervals.
Decommissioning, Storage and Transport 12.3 Storage Pre–condition: The machine must be adequately packed. Moisture and frost. CAUTION . Store the machine in a dry, frost ---free room. . Prevent entry of moisture and condensation. Advice can be obtained from KAESER on suitable storage and initial start ---up.
Decommissioning, Storage and Transport Fig. 30 Transporting slung from a crane hook. 12.5 Disposal Pre–condition: Machine is decommissioned. When disposing of a machine, drain out all liquids and remove dirty filters. Parts contaminated with oil must be disposed of in accordance with local environment protection regulations.
SAFETY VALVES Design DN 8 PN 50 -25 bis 180 °C Type tested SVW/SVWN/SVWC Applications: ð Suitable for compressed, similar non-inflammable and non-toxic gases; free discharge, not suitable for fluids and vapours. Types: ð 2.0401 (brass) SVWC ð 1.4104 (stainless steel) SVWN ð...
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SAFETY VALVES Design DN 8 PN 50 -25 bis 180 °C Type tested SVW/SVWN/SVWC Discharge capacity qm [m³/h] qm [m³/h] [bar] bei 0°C/760 Torr [bar] bei 0°C/760 Torr 13,6 571,8 19,3 595,8 37,6 619,7 48,1 643,6 58,6 667,6 69,2 691,5 81,2 715,4 93,2...
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Sicherheitsventil / safety valve Typ L08 Zulassung / homologation : CE 97/23/EG Druckbereich / pressure range: 0,3-47,0 bar Anschlussgewinde / inlet connection : G ¼“, G 3/8 oder / or G 1/2“ Ausgangsgewinde / outlet connection: frei abblasend / free outlet Nennweite / nominal size: 8 mm Temperaturbereich / temperature range:...
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