KAESER KOMPRESSOREN MOBILAIR M250E Manuals

Manuals and User Guides for KAESER KOMPRESSOREN MOBILAIR M250E. We have 1 KAESER KOMPRESSOREN MOBILAIR M250E manual available for free PDF download: Operator's Manual

KAESER KOMPRESSOREN MOBILAIR M250E Operator's Manual (296 pages)

Portable Rotary Screw Compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 25 MB

Table of Contents
3
Regarding this Document Using this Document
13
Further Documents
13
Copyright
13
Symbols and Labels
13
Warnings
13
Tab. 1 Danger Levels and Their Definition (Personal Injury)
13
Potential Damage Warnings
14
Other Alert Notes and Their Symbols
14
Tab. 2 Danger Levels and Their Definition (Damage to Property)
14
Technical Data Nameplate
16
Options
16
Tab. 3 Nameplate
16
Compressed Air Distributor
17
Air Treatment
17
Low Temperature Equipment
17
Fig. 1 Option Label MOBILAIR M250E / M255E with Options
17
Tab. 4 Compressed Air Distributor Option
17
Tab. 5 Air Treatment Options
17
Tab. 6 Low Temperature Equipment Option
17
Automatic Start/Stop
18
DUAL Control
18
GSM/GPS Modem
18
Machine (Without Options)
18
Sound Pressure Level [Db(A)]
18
Tightening Torque
18
Tab. 7 Automatic Start/Stop
18
Tab. 8 DUAL Control
18
Tab. 9 GSM/GPS Modem
18
Tab. 10 Guaranteed Sound Pressure Level [Db(A)]
18
Ambient Conditions
19
Tab. 11 Torques for M4-M8 Screws
19
Tab. 12 Torques for M10-M24 Screws
19
Tab. 13 Torque Cover Fixing Screws Oil Separator Tank
19
Tab. 14 Torques for Lifting Eye Screws
19
Tab. 15 Ambient Conditions
19
Additional Specifications
20
Compressor
20
Gauge Working Pressure and Flow Rate
20
Tab. 16 Gauge Working Pressure and Flow Rate, M250E / 460 V / 60 Hz
20
Tab. 17 Gauge Working Pressure and Flow Rate, M255E / 460 V / 60 Hz
20
Tab. 18 Gauge Working Pressure and Flow Rate, M250E / 575 V / 60 Hz
20
Safety Relief Valve
21
Temperature
21
Tab. 19 Gauge Working Pressure and Flow Rate, M255E / 575 V / 60 Hz
21
Tab. 20 Safety Relief Valve Actuating Pressure
21
Tab. 21 Machine Temperature
21
Tab. 22 Switching to LOAD Mode
21
Tab. 23 Machine Temperature
21
Compressor Air Filter Maintenance Switch
22
Compressed Air Outlet
22
Compressed Air Quality
22
Tab. 24 Maintenance Switch Switching Point
22
Tab. 25 Compressed Air Outlet Butterfly Valve
22
Tab. 26 Ambient Temperature
22
Tab. 27 Interrelation between Compressed Air Treatment and Compressed Air Quality
22
Cooling Oil Recommendation
23
Cooling Oil Charge
23
Checking the Filling Volume of the Condensate Collection Tank
23
Tab. 28 Cooling Oil Recommendation
23
Tab. 29 Cooling Oil Charge
23
Drive Motor
24
Make
24
Drive Motor Rated Power
24
Tab. 30 Filling Volume of Internal Condensate Collection Tank
24
Tab. 31 Drive Motors by Rated Power 175 Hp
24
Tab. 32 Drive Motors by Rated Power 214.6 Hp
24
Tab. 33 Technical Specifications for M250E Drive Motors
24
Maximum Rated Current
25
Tab. 34 Technical Specifications for M255E Drive Motors
25
Tab. 35 Maximum Rated Current M250E
25
Tab. 36 Maximum Rated Current M255E
25
Tab. 37 Maximum Rated Current M250E
25
Electrical Connection
26
Power Supply
26
Fig. 2 Three-Phase Star (Wye System); 4 Wire; Center Point Solidly Grounded
26
Tab. 38 Maximum Rated Current M255E
26
Power Supply Specifications
27
Fig. 3 Three-Phase Star (Wye System); 3 Wire; Grounded Center Point Solidly Grounded
27
Tab. 39 Connection Type for Rated Voltage 460V/575V/M250E
27
Tab. 40 Sconnection Type for Rated Voltage 460V/575V/M255E
27
Fan Motor
28
Fan Motor Rated Power
28
Options
28
Low-Temperature Equipment
28
Measuring Point Connection
28
Tab. 41 Fan Motor Rated Power 60 Hz
28
Tab. 42 Ambient Conditions, Low-Temperature Equipment
28
Tab. 43 Auxiliary Heater Power
28
Tab. 44 Measuring Point Connection
28
Safety and Responsibility Basic Instructions
29
Specified Use
29
Incorrect Use
29
Operator Responsibilities
29
Observe Statutory and Accepted Rules and Regulations
29
Determining Suitable Personnel
30
Complying with Inspection Schedules and Accident Prevention Regulations
30
Dangers
31
Safely Dealing with Sources of Danger
31
Tab. 45 Inspection Intervals According to Ordinance on Industrial Health and Safety
31
Organizational Measures
33
Danger Areas
34
Safety Devices
34
Service Life of Safety Functions
34
Tab. 46 Danger Areas
34
Tab. 47 Category and Performance Level
34
Safety Signs
35
Fig. 4 Locations of Safety Signs on the Outside of the Machine
35
Tab. 48 Safety Signs
36
Fig. 5 Locations of Safety Signs on the Inside of the Machine
37
Fig. 6 Locations of Safety Signs on the Inside of the Machine (Top View)
38
Tab. 49 Safety Signs
38
Noise Control Requirements
39
Emergencies
39
Correct Actions in the Event of a Fire
39
Fig. 7 Position of Safety Signs on the Control Cabinet
39
Treating Injuries from Handling Operating Fluids/Materials
40
Warranty
41
Noise Emissions Warranty
41
Identifying the Effects of Improper Modifications
41
Environmental Protection
42
Design and Function Bodywork
43
Fig. 8 Overview of Bodywork
44
Machine Layout
45
Machine Function
45
Fig. 9 Example M250E, 175 Hp, 400V/50Hz, Sigma
45
Fig. 10 Example M250E, 132 Kw, 400V/50Hz, Sigma
46
Operating Modes and Control Modes
47
Machine Operating Modes
47
PROPORTIONAL Control Mode
47
Safety Devices
48
Monitoring Functions with Shut-Down
48
Further Safety Devices
48
SIGMA CONTROL SMART Control Panel
48
Fig. 11 Overview of SIGMA CONTROL SMART Control Panel
48
Draining the Cooling Oil and Condensate
49
Tab. 50 Control Unit Keys and Indicators
49
Draining Condensate According to Operating Conditions
50
Options
50
Fig. 12 Drain Device - Symbols and Arrangement of Shut-Off Valves
50
Air Treatment
51
Auxiliary Heater
51
Fig. 13 Filter Combination
51
Tab. 51 Temperature Set-Point Value
51
Automatic Operating Modes
52
Fig. 14 Electric Auxiliary Heater
52
Tab. 52 Set the Measuring Point Using the Directional Control Valve
53
GSM/GPS Unit
54
Document Bag
54
Fig. 15 Measuring Point Connection
54
Fig. 16 Location of the GSM/GPS Unit Inside the Machine
54
Fig. 17 Document Bag Option
55
Installation and Operating Conditions
56
Ensuring Safety
56
Installation Conditions
56
Note the Conditions for Stationary Installation
57
Fig. 18 Minimum Distances from Excavations/Slopes/Walls
57
Tab. 53 Maximum Inclined Position
57
Fig. 19 Flow of Cooling Air Inside the Machine
58
Fig. 20 Minimum Distance if Several Machines Are Set up
58
Comply with the Specified Ambient Temperature
59
Installation
60
Ensuring Safety
60
Reporting Transport Damage
60
Securing the Parked Machine
60
Fitting the Machine Feet
61
Fig. 21 Mounting Machine Foot/Rubber Pad
61
Electrical Connection
62
Network Conditions
62
Power Supply Disconnecting Device
62
Using the External Condensate Collection Tank
62
Tab. 54 On-Site Power Supply Disconnecting Device
62
Fig. 22 Drain Device - Symbols and Arrangement of Shut-Off Valves
63
Initial Start-Up Ensuring Safety
64
Before Initial Start-Up (or Recommissioning)
65
Instructions to be Observed before Commissioning or Recommissioning
65
After Storing the Machine for a Long Period
65
Tab. 55 Measures for Re-Commissioning the Compressor after a Long Period of Storage
65
Setting the Overload Relay
66
Setting the Motor Overload Protection Switch
66
Setting the Voltage Measuring Relay
66
Draining Condensate According to Operating Conditions
66
Fig. 23 Draining Condensate Internally/Externally
67
Low-Temperature Operation (Winter)
68
Following the Pre-Heating Time of the Auxiliary Heater
68
Tab. 56 Example of Pre-Heat Time for the Electrical Auxiliary Heater
68
Tab. 57 "Do Not Start the Machine" Information Sign
68
Note the Automatic Operating Modes
69
Note the Automatic Start/Stop
69
Note the DUAL Control
69
Tab. 58 Safety Sign for Automatic Starting
69
Tab. 59 Safety Sign for Automatic Starting
69
Operation
71
Ensuring Safety
71
Observing Environmental Impacts
72
Environmental Impact: Thunderstorm
72
Environmental Impact: Low Temperature
72
Switching on the Machine
73
Connecting the Power Supply Cable
73
Fig. 24 Machine Cable Shaft
73
Overview of Fittings
74
Fig. 25 Connecting the Plug-In Connection System
74
Tab. 60 Color Coding L1, L2, L3, GRD
74
Fig. 26 Arrangement of SIGMA CONTROL SMART Operating Unit and Fittings
75
Fig. 27 SIGMA CONTROL SMART Operating Unit Keys and Displays
75
Preparing the Machine to Start
76
Switching on the Drive Motor
76
Running up the Machine to Operating Temperature
76
Fig. 28 Ready Indicator Display
76
Switching the Machine to LOAD Operation
77
Setting the Compressed Air Discharge Pressure
77
Fig. 29 Quick Access Adjustment Compressed Air Output Pressure
78
Fig. 30 Setting the Compressed Air Discharge Pressure
78
Switching off
79
Observing the Back Pressure Indicator
80
Switching off the Controller Voltage
80
Switching off the On-Site Power Supply Disconnecting Device
80
Disconnecting the CAM-LOK Plug-In Connection System
80
Shutting down Machine in the Event of an Emergency
80
Fig. 31 Switching off in an Emergency
81
Checking the Ambient Temperature
82
Confirming Alarm and Warning Messages
82
Confirming and Acknowledging Alarm Messages
82
Confirming and Acknowledging Warning Messages
82
Checking the Level of the Condensate Collection Tank
83
Checking the Internal Condensate Collection Tank
83
Checking the External Condensate Collection Tank
83
Cleaning the Machine after Operation
83
Cleaning the Exterior of the Machine
84
Fig. 32 Closed Floor Pan Bung
84
Cleaning the Interior of the Machine
85
Tab. 61 Suitable Compressed Air Range for Cleaning
85
Operating the Options
86
Note the Automatic Operating Modes
86
Fig. 33 Measuring Point Information Sign
87
Fault Recognition and Rectification
88
Basic Instructions
88
Analyzing SIGMA CONTROL SMART Messages
88
Alarm Message on the Controller (Machine Off)
88
Tab. 62 Alarm Messages and Troubleshooting Concerning the Drive Motor
88
Tab. 63 Alarm Messages and Troubleshooting Concerning "Compressor Fault
89
Tab. 64 Alarm Messages and Troubleshooting Concerning "Controller Fault
89
Warning Message on the Controller
90
Tab. 65 Alarm Messages and Troubleshooting Concerning "General Faults
90
Drive Motor Faults and Alarms
91
Drive Motor Refuses to Start or Stops
91
Tab. 66 Warning Messages and Measures Relating to the Compressor
91
Tab. 67 General Warning Messages and Measures
91
Compressor Faults and Alarms
92
Working Pressure too High
92
Tab. 68 Fault: "Drive Motor Refuses to Start or Stops
92
Tab. 69 Fault: Working Pressure too High
92
Working Pressure too Low
93
Safety Relief Valve Blowing off
93
Machine Overheating
93
Tab. 70 Fault: Working Pressure too Low
93
Tab. 71 Fault: Safety Relief Valve Blowing off
93
Too Much Oil Residue in the Compressed Air
94
Tab. 72 Fault: Machine Overheating
94
Tab. 73 Alarm: "Too Much Oil Residue in the Compressed Air
94
Oil Flows from the Compressor Air Filter after Shutdown
95
Tab. 74 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown
95
10 Maintenance
96
Ensuring Safety
96
Tab. 75 Advise Others that the Machine Is Being Serviced
96
Adhere to the Maintenance Messages on the Controller
97
Evaluating the Maintenance Message
97
Completing the Maintenance
98
Tab. 76 Maintenance Messages and Required Measures
98
Following the Maintenance Plans
99
Logging Maintenance Work
99
Regular Maintenance Tasks
99
Tab. 77 Maintenance Intervals and Regular Maintenance Tasks
99
Tab. 78 Regular Machine Maintenance Tasks
102
Tab. 79 Regular Maintenance Task Options
102
Motor Maintenance
103
Servicing the Motor Bearings on the Drive Motor
103
Tab. 80 Specific Message Code for "Service Motor Bearings
103
Fig. 34 Positions of the Grease Nipples
104
Fan Motor Maintenance
105
Fig. 35 Lubricating the Drive Motor Bearings
105
Compressor Maintenance
106
Checking the Cooling Oil Level
106
Fig. 36 Checking the Cooling Oil Level
106
Filling and Replenishing with Cooling Oil
107
Changing the Cooling Oil
108
Tab. 81 Specific Message Code for "Change Cooling Oil
108
Fig. 37 Drain Device - Symbols and Arrangement of Shut-Off Valves
110
Replacing the Compressor Oil Filter
111
Tab. 82 Specific Message Code for "Replace Oil Filter
111
Fig. 38 Replacing the Oil Filter
112
Servicing the Control Valve Dirt Trap
113
Fig. 39 Servicing the Dirt Trap on the Oil Separator Tank
114
Changing the Oil Separator Cartridge
115
Fig. 40 Changing the Oil Separator Cartridge
117
Fig. 41 Removing Wearing Parts
118
Servicing the Compressor Air Filter
120
Tab. 83 Specific Message Code for "Service Air Filter
120
Fig. 42 Servicing the Compressor Air Filter
121
Cleaning the Compressed Air Aftercooler
122
Fig. 43 Cleaning the Filter Element
122
Tab. 84 Suitable Compressed Air Range for Cleaning
123
Fig. 44 Cleaning the Compressed Air Aftercooler
124
Servicing the Dirt Trap on the Centrifugal Separator
125
Fig. 45 Cleaning the Dirt Trap
126
Checking Safety Relief Valves
127
Checking the Excessive Temperature Shut-Down Function
127
Check the EMERGENCY STOP Push Button
127
Tab. 85 Shut-Down at Excessive Temperature
127
Cleaning the Oil Cooler
128
Fig. 46 Check the EMERGENCY STOP Push Button
128
Cleaning the Oil Cooler
129
Fig. 47 Cleaning the Oil Cooler
129
Tab. 86 Suitable Compressed Air Range for Cleaning
129
Checking/Emptying the Condensate Collection Tank
131
Fig. 48 Unlocking the Venting Coupling
131
Emptying the Condensate Collection Tank
132
Checking the Condensate Drain Line
132
Checking the Screw Connections
133
General Guideline Values for Tightening Torques
133
Specific Guideline Values for Tightening Torques
133
Sealed Screw Connections
133
Check Sound Insulation Material
135
Checking the Doors
136
Service Rubber Sealing Strips
136
Checking Function of Closed Doors
136
Checking Connection Elements of Doors
137
Checking/Replacing Hose Lines
137
Replace the Pressure Hoses of the Compressor
137
Draining Accumulated Liquid Inside the Machine
137
Fig. 49 Closed Floor Pan Plug
138
Have the Main Contactor Replaced
139
Maintenance for Optional Items
139
Servicing the Filter Combination
139
Tab. 87 Specific Message Code for "Service Main Contactor
139
Fig. 50 Compressed Air Filter Combination
140
Fig. 51 Draining the Condensate
140
Fig. 52 Changing the Filter Elements
142
Tab. 88 Replacing the Filter Elements
143
Documenting Maintenance and Service Work
145
Tab. 89 Maintenance Log
145
11 Spares, Operating Materials, Service
146
Note the Nameplate
146
Ordering Spare Parts and Operating Fluids/Materials
146
Kaeser Air Service
146
Tab. 90 Compressor Spare Parts
146
Tab. 91 Drive Motor Spare Parts
146
Replacement Parts for Service and Repair
147
Spare Parts Overview
147
12 Decommissioning, Storage and Transport
215
Decommissioning
215
Temporary Decommissioning
215
Long-Term Decommissioning
215
Tab. 92 "Temporarily Decommissioned" Information Notice
215
Tab. 93 Definition of Long-Term Decommissioning
215
Transport
216
Tab. 94 Long-Term Decommissioning Checklist
216
Tab. 95 "Long-Term Decommissioning" Information Sign
216
Safety
217
Transporting the Machine by Crane
217
Transporting the Machine with a Forklift Truck
218
Fig. 53 Crane Lifting Eye Information Sign
218
Fig. 54 Prepare for Transport Using a Forklift Truck
219
Fig. 55 Lifting the Machine with a Forklift Truck
220
Transporting the Machine Locally on Site
221
Fig. 56 Transporting the Machine with a Forklift Truck
221
Tab. 96 Maximum Load Force of Lashing Eye
221
Transporting the Machine as Load
222
Fig. 57 Improperly Lashed down Across Bodywork
222
Tab. 97 Maximum Load Force of Lashing Eye
222
Storage
223
Fig. 58 Properly Lashed down Using Lashing Points on Support Frame
223
Disposal
224
Draining Operating Fluids
224
Tab. 98 Machine Fluids
224
Draining the Condensate
225
Removing Filters/Filter Elements
225
Disposing of the Machine
225
Tab. 99 Machine Filters/Filter Elements
225
Tab. 100 Machine Option Filters/Filter Elements
225
13 Annex
226
Labeling
226
Pipeline and Instrument Diagram (P&I Diagram)
226
Fig. 59 Labeling M250E/M255E/60Hz
226
Dimensional Drawing
229
Electrical Diagram
231
Operator Manual for Compressed Air Filter Combination
261
Installing CAM-LOK
289

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