KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 Manuals

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KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 Manual (418 pages)

Portable Rotary Screw Compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 24.06 MB

Table of Contents
3
Regarding this Document Using this Document
15
Further Documents
15
Copyright
15
Symbols and Labels
15
Warnings
15
Potential Damage Warnings
16
Tab. 1 Danger Levels and Their Definition (Personal Injury)
16
Tab. 2 Danger Levels and Their Definition (Damage to Property)
16
Other Alert Notes and Their Symbols
17
Technical Data Nameplate
18
Vehicle Identification Number
18
Options - Options Label
18
Tab. 3 Nameplate
18
Compressed Air Treatment Devices
19
Tool Lubricator
19
Compressed Air Distributor
19
Tab. 4 Extract from the Options Label
19
Tab. 5 Air Treatment Options
19
Tab. 6 Tool Lubricator Option
19
Tab. 7 Compressed Air Distributor Option
19
Low Temperature Equipment
20
Equipment for Fire Hazard Areas
20
Automatic Engine Start/Stop
20
GSM/GPS Unit
20
Lighting
20
Tab. 8 Low Temperature Equipment Options
20
Tab. 9 Optional Equipment for Fire Hazard Areas
20
Tab. 10 Automatic Engine Start/Stop
20
Tab. 11 GSM/GPS Unit
20
Tab. 12 Lighting Options
20
Generator
21
Closed Floor Pan
21
Anti-Theft Device
21
Pedestrian Protection
21
Machine (Without Options)
21
Sound Pressure Level
21
Tab. 13 Generator Option
21
Tab. 14 Closed Floor Pan Option
21
Tab. 15 Anti-Theft Device Option
21
Tab. 16 Pedestrian Protection Option
21
Tightening Torque
22
Tab. 18 Torques for M4-M8 Screws
22
Tab. 19 Torques for M10-M24 Screws
22
Tab. 20 Torques for Lifting Eye Screws
22
Tab. 21 Torque Cover Fixing Screws Oil Separator Tank
22
Ambient Conditions
23
Additional Specifications
23
Chassis
23
Chassis Options
23
Machines with Stationary Frame Design
23
Weight of Machines with Stationary Frame Design
23
Tab. 22 Ambient Conditions
23
Tab. 23 Weight of the Machine
23
Compressor
24
Working Gauge Pressure and Volumetric Flow Rate
24
Compressed Air Outlet
24
Safety Valves
24
Temperature
24
Tab. 24 Working Gauge Pressure and Volumetric Flow Rate
24
Tab. 25 Compressed Air Distributor
24
Tab. 26 Safety Valve Opening Pressure
24
Tab. 27 Required Temperatures Readiness to Switch to LOAD Mode
24
Tab. 28 Airend Discharge Temperature
24
Cooling Oil Recommendation
25
Tab. 29 Cooling Oil Recommendation
25
Tab. 30 Cooling Oil Recommendation (Food Processing)
25
Cooling Oil Charge
26
Engine
26
Engine Specification
26
Tab. 31 Cooling Oil Charge
26
Tab. 32 Kubota / V 3307-CRT Engine Specifications
26
Oil Recommendation
27
Tab. 33 Engine Specifications
27
Fuel Recommendation
28
Tab. 34 Engine Oil Recommendation
28
Tab. 35 Initial Engine Oil Quantity
28
Engine Coolant Recommendation
29
Tab. 36 Water Quality Parameters for Cooling Water
29
Fluid Volumes
30
Batteries
30
Tab. 37 Initial Filling of Engine Water Cooler
30
Tab. 38 Fluid Volumes
30
Tab. 39 Batteries
30
Options
31
Air Treatment Options
31
Tab. 40 Road Breaker Lubricant Recommendation
31
Tab. 41 Fresh Air Filter Conditions
31
Tab. 42 Interrelation between Compressed Air Treatment and Compressed Air Quality
31
Low Temperature Equipment
32
Auxiliary Electrical Systems
32
Tab. 43 Ambient Conditions, Low Temperature Equipment
32
Tab. 44 Power Supply Connection Details
32
Tab. 45 Technical Data - Coolant Pre-Heating Device
32
Generator
33
Tab. 46 Battery Charger Specification
33
Tab. 47 Generator Specification
33
Tab. 48 Flow Rate in Generator Mode
33
Tab. 49 Connection Sockets
34
Tab. 50 Circuit Breaker
34
Tab. 51 Generator Operating Limits
34
GSM/GPS Unit
35
Tab. 52 Maximum Three-Phase Mains Loading
35
Tab. 53 Maximum Single-Phase Mains Loading
35
Tab. 54 Power Reduction at Elevated Ambient Temperatures
35
Tab. 55 GSM/GPS Unit
35
Safety and Responsibility Basic Instructions
36
Specified Use
36
Incorrect Use
36
User's Responsibilities
36
Observe Statutory and Universally Accepted Regulations
36
Determining Personnel
37
Complying with Inspection Schedules and Accident Prevention Regulations
37
Taking the Machine for General Inspection
38
Tab. 56 Inspection Intervals According to Ordinance on Industrial Health and Safety
38
Tab. 57 General Inspection Intervals
38
Documenting the Mileage of the Machine as Trailer
39
Dangers
39
Safely Dealing with Sources of Danger
39
Safe Machine Operation
42
Organizational Measures
45
Danger Areas
46
Safety Devices
46
Safety Signs
46
Tab. 58 Danger Areas
46
Fig. 1 Location of Safety Signs (Outside)
47
Fig. 2 Location of Safety Signs (Inside)
50
Tab. 59 Safety Signs
50
Tab. 60 Safety Signs
50
Noise Control Requirements
51
Generator Operation
52
Comply with the Protective Measures against Dangerous Electric Current
52
Safe Generator Operation
52
Connecting Extension Cables
52
Do Not Exceed the Maximum Supply System Load
53
Perform Regular Generator Inspections
53
Emergencies
53
Correct Actions in the Event of a Fire
53
Treating Injuries from Handling Operating Fluids/Materials
54
Warranty
54
Noise Emissions Warranty
55
Identifying the Effects of Improper Modifications
55
Environmental Protection
56
Design and Function Bodywork
57
Fig. 3 Overview of Bodywork
57
Machine Layout
58
Fig. 4 Right-Hand Door Opened
58
Fig. 5 Left-Hand Door Opened
58
Machine Function
59
Fig. 6 View from Above, Machine Roof Removed
59
Fig. 7 Machine Overview
60
Operating Modes and Control Mode
61
Machine Operating Modes
61
MODULATING Control
61
Safety Devices
62
Monitoring Functions with Shut-Down
62
Further Safety Devices
62
Fig. 8 Continuous Regulation of Volumetric Flow (Standstill)
62
Battery Isolating Switch
63
SIGMA CONTROL SMART Control Panel
63
Fig. 9 Battery Isolating Switch
63
Fig. 10 SIGMA CONTROL SMART Operator Panel - Overview
63
Exhaust Gas After-Treatment
64
Tab. 61 Instrument Panel Keys and Displays
64
Engine Optimisation
65
Exhaust Gas Treatment System
65
Options
66
Fig. 11 Principle of Treatment Devices
66
Air Treatment Options
67
Fig. 12 Compressed Air Options
67
Tab. 62 Compressed Air Quality With/Without Heat Exchanger
68
Fig. 13 Tool Lubricator
70
Fig. 14 Principle Tool Lubricator
70
Auxiliary Electrical Systems
71
Low Temperature Equipment Options
71
Options for Operating in Fire Hazard Areas
72
Generator Option
72
Tab. 63 Generator / Compressor Operation
72
Fig. 15 Instrument Panel - Generator Control Box, 400 V Three Phase
73
Tab. 64 Generator Operating Modes
73
Fig. 16 Instrument Panel - Generator Control Box, 230 V Three Phase
74
Fig. 17 Control Panel, Generator Control Box, 115 V AC
74
Start/Stop/Automatic Options
75
GSM/GPS Unit
75
Transport Options
76
Frame Design Options for Stationary Machines
76
Closed Floor Pan Option
76
Tab. 65 Stationary Machines
76
Pedestrian Protection Option
77
Fig. 18 Position of Service Openings in the Closed Floor Pan
77
Fig. 19 Drain Points for Oil and Coolant from Engine and Compressor
77
Installation and Operating Conditions
78
Ensuring Safety
78
Installation Conditions
78
Fig. 20 Minimum Distance from Excavations/Slopes and Walls
78
Machine with Stationary Frame Structure
79
Installation
80
Ensuring Safety
80
Reporting Transport Damage
80
Perform Regular Maintenance on the Chassis
80
Installing a Machine with Stationary Frame Superstructure on a Truck Platform
80
Have the "Remote on Contact" of the Automatic Start/Stop System Connected
81
Electrical Connection of the Battery Charger
81
Initial Start-Up Ensuring Safety
82
Before Initial Start-Up (or Recommissioning)
82
Instructions to be Observed before Commissioning or Recommissioning
82
Special Measures for Recommissioning after Storage
83
Checking Installation and Operating Conditions
83
Tab. 66 Measures for Recommissioning the Compressor after a Long Period of Storage
83
Tab. 67 Positioning and Operating Conditions Checklist
83
Low-Temperature Operation (Winter)
84
Jump Starting the Machine
84
Fig. 21 Jumper Cable Connection Diagram
85
Starting up Low-Temperature Equipment
86
Commissioning Electrical Equipment
87
Activating the Generator
87
Checking the Generator
87
Fig. 22 Connect Auxiliary Electrical Systems
87
Fig. 23 Insulation Monitoring - 400 V Three-Phase Generator
88
Fig. 24 Insulation Monitoring - 230 V Three-Phase Generator
88
Fig. 25 Insulation Monitoring - 115 V Single Phase Generator
89
Tab. 68 Test Instructions for a Generator with an Earth Leak Detection Device
89
Operation
90
Ensuring Safety
90
Starting and Stopping
91
Fig. 26 Starting Instruments
91
Follow the Brief Operating Instructions
92
Fig. 27 Instrument Panel Keys and Indicators
92
Fig. 28 Brief Instructions on Starting Procedure
92
Commissioning the Machine
93
Fig. 29 Brief Instructions on Stopping Procedure
93
Starting the Machine
94
Fig. 30 "Battery Isolating Switch
94
Setting the Compressed Air Discharge Pressure
95
Fig. 31 Quick Access Adjustment Compressed Air Output Pressure
96
Shutting down the Machine
97
Fig. 32 Setting the Compressed Air Discharge Pressure
97
Shutting down in an Emergency
99
Confirming Alarm and Warning Messages
99
Confirming Alarm Messages
99
Confirming Warning Messages
100
Operating the Options
100
Operating the Machine with the "Automatic Start/Stop" Option
100
Fig. 33 Preparing Start of the "Automatic Start/Stop
101
Operating the Tool Lubricator
102
Fig. 34 Setting the Tool Lubricator
103
Using the Low-Temperature Equipment
104
Bypassing and Activating the Heat Exchanger
104
Tab. 69 Shut-Off Valve Position and Selected Compressed Air Quality
104
Fig. 35 Heat Exchanger Without Bypass Operation (with Compressed Air Heating)
105
Fig. 36 Heat Exchanger with Bypass Operation (no Compressed Air Heating)
106
Generator Operation
107
Tab. 70 Shut-Off Valve Position and Selected Compressed Air Quality
107
Cleaning the Machine after Operation
108
Refuelling the Machine
109
Use the Correct Type of Fuel
109
Fig. 37 Filling the Tank with the Correct Fuel Type
110
Tab. 71 Measures Required Should the Fuel Tanks be Filled with the Incorrect Fuel Type
110
Filling the Fuel Tank at a Pump by Means of a Refuelling Nozzle
111
Tab. 72 Fuel Type/Fuel Specification
111
Filling the Fuel Tank on a Construction Site by Means of a Canister
112
Fault Recognition and Rectification
113
Basic Instructions
113
Analysing SIGMA CONTROL SMART Messages
113
Alarm Messages on the Controller (Machine Off)
113
Tab. 73 Alarm Messages and Actions Concerning the Motor/Engine
114
Tab. 74 Alarm Messages and Actions Concerning the Compressor Unit
115
Tab. 75 Alarm Messages and Actions Concerning the Controller
115
Warning Messages on the Controller
116
Tab. 76 Alarm Messages and Troubleshooting in "General Faults
116
Tab. 77 Warning Messages and Measures Relating to the Engine
117
Tab. 78 Warning Messages and Measures Relating to the Compressor
117
Evaluating Engine Faults and Alarms
118
Engine Refuses to Start or Does Not Turn over
118
Tab. 79 General Warning Messages and Measures
118
Engine Does Not Reach Full Speed
119
Analysing Compressor Faults and Alarms
119
Working Pressure too High
119
Tab. 80 Fault: Engine Refuses to Start or Comes to a Stop
119
Tab. 81 Alarm: "Engine Does Not Reach Full Speed
119
Tab. 82 Fault: Working Pressure too High
119
Working Pressure too Low
120
Safety Valve Blows off
120
Machine Overheating
120
Tab. 83 Fault: Working Pressure too Low
120
Tab. 84 Fault: Safety Valve Blowing off
120
Too Much Oil Residue in the Compressed Air
121
Tab. 85 Fault: Machine Overheating
121
Tab. 86 Alarm: "Too Much Oil Residue in the Compressed Air
121
Oil Flows from the Compressor Air Filter after Shutdown
122
High Moisture Content in the Compressed Air
122
Generator Faults and Alarms
122
No Voltage or too Low a Voltage from the Generator
122
Tab. 87 Alarm: "Oil Flows from the Compressor Air Filter after Shutdown
122
Tab. 88 Fault: High Moisture Content in the Compressed Air
122
Generator Voltage too High
123
Tab. 89 Fault: no Voltage or too Low a Voltage from the Generator
123
Tab. 90 Fault: Generator Voltage too High
123
10 Maintenance
124
Ensuring Safety
124
Tab. 91 Advise Others that the Machine Is Being Serviced
124
Note the Maintenance Messages on the Controller
125
Evaluating the Maintenance Message
125
Concluding the Maintenance
126
Maintenance Schedules
126
Logging Maintenance Work
126
Preventive Maintenance
126
Tab. 92 Maintenance Messages and Required Actions
126
Maintenance Tasks after Commissioning
127
Regular Maintenance Tasks
127
Tab. 93 Maintenance Tasks on the Machine after Commissioning
127
Tab. 94 Maintenance Intervals and Regular Maintenance Tasks
128
Tab. 95 Regular Machine Maintenance Tasks
131
Drive Engine Maintenance
132
Tab. 96 Regular Maintenance Task Options
132
Coolant Cooler Maintenance
133
Fig. 38 Checking the Coolant Level
134
Fig. 39 Recommended Mixture Ratio for Coolant
135
Tab. 97 Coolant Mixture Table
136
Fig. 40 Draining the Coolant from the Engine Coolant Cooler
137
Fig. 41 Draining the Coolant from the Engine Coolant Cooler (Closed Floor Pan/Stationary Machine)
138
Engine Air Filter Maintenance
139
Fig. 42 Cleaning the Dust Evacuator Valve
140
Fig. 43 Engine Air Filter Maintenance
140
Fig. 44 Cleaning the Filter Element
141
Fuel System Maintenance
142
Fig. 45 Service Fuel System
142
Fig. 46 Bleeding the Fuel System
143
Fig. 47 Warning Message: Fuel Filter Water Level
144
Fig. 48 Empty the Fuel Prefilter and Water Separator
144
Fig. 49 Change the Fuel Prefilter Cartridge
145
Fig. 50 Fuel Filter Maintenance
146
Checking the Engine Oil Level
147
Fig. 51 Checking the Engine Oil Level
147
Engine Oil Filling and Topping up
148
Changing the Engine Oil
148
Fig. 52 Draining the Engine Oil
149
Fig. 53 Draining the Engine Oil (Stationary Machine)
150
Replace the Engine Oil Filter
151
Fig. 54 Change the Oil Filter
151
Drive Belt Maintenance
152
Fig. 55 Belt Guard Attachment
153
Fig. 56 Checking the Drive Belt Seating
153
Fig. 57 Manually Checking the Belt Tension
154
Fig. 58 Tension the Belt
155
Fig. 59 Replace the Drive Belt
156
Battery Maintenance
157
Fig. 60 Safety Signs - Warning Labels on the Battery
157
Tab. 98 Starter Battery Charge Level
158
Change the Oil Separator Cartridge
159
Fig. 61 Change the Oil Separator Cartridge
159
Servicing the Components of the Emission After-Treatment System
160
Compressor Maintenance
160
Check the Cooling Oil Level
160
Cooling Oil Filling and Topping up
161
Fig. 62 Check the Cooling Oil Level
161
Changing the Cooling Oil
162
Fig. 63 Draining the Compressor Cooling Oil
163
Fig. 64 Draining the Cooling Oil (Closed Floor Pan - Stationary Machine)
164
Replacing the Compressor Oil Filter
165
Fig. 65 Change the Oil Filter
166
Oil Separator Tank Dirt Trap Maintenance
167
Fig. 66 Oil Separator Tank Dirt Trap Maintenance
167
Changing the Oil Separator Cartridge
168
Fig. 67 Changing the Oil Separator Cartridge
169
Compressor Air Filter Maintenance
171
Fig. 68 Compressor Air Filter Maintenance
171
Fig. 69 Cleaning the Filter Element
172
Cleaning the Cooler
173
Cleaning the Compressor Cooler and Engine Radiator
173
Cleaning the Compressed Air After-Cooler
174
Fig. 70 Cleaning the Compressor Cooler and Engine Radiator
174
Checking Screw Connections
175
Fig. 71 Cleaning the Compressed Air After-Cooler
175
Check Wing Doors
176
Check Sound Proofing Material
177
Maintenance of Rubber Sealing Strips
177
Performing Maintenance Tasks on the Chassis
178
Check/Replace Hose Lines
178
Replace the Fuel Lines of the Drive Engine
178
Replace the Pressure Hoses of the Engine
179
Replace the Pressure Hoses of the Compressor
179
Check Safety Functions
179
Check the EMERGENCY STOP Push Button
179
Have the Actuating Pressure of the Safety Relief Valve Checked
180
Having Excessive Temperature Shut-Down Function Checked
180
Tab. 99 Safety Valve Actuating Pressure
180
Maintenance for Optional Items
181
Tool Lubricator Maintenance
181
Tab. 100 Safety Shut-Down at Excessive Airend Discharge Temperature
181
Fig. 72 Tool Lubricator Maintenance
182
Centrifugal Separator Maintenance
183
Fig. 73 Cleaning the Condensate Drain
183
Combination Filter Maintenance
184
Fig. 74 Filter Combination
185
Fig. 75 Combination Filter Maintenance
185
Fresh Air Filter Maintenance
188
Fig. 76 Fresh Air Filter Maintenance
188
Spark Arrestor Maintenance
191
Fig. 77 Cleaning the Spark Arrestor (Floor Pan with Service Openings)
191
Fig. 78 Cleaning the Spark Arrestor (Sealed Floor Pan)
192
Maintaining the Generator Drive Belt
193
Fig. 79 Securing the Belt Guard at the Generator
194
Fig. 80 Tighten the Generator Drive Belt
195
Draining Liquid Accumulation Within the Machine
196
Documenting Maintenance and Service Work
198
Tab. 101 Maintenance Log
198
11 Spares, Operating Materials, Service
199
Note the Nameplate
199
Ordering Consumable Parts and Operating Fluids/Materials
199
Tab. 102 Compressor Consumables
199
Kaeser Air Service
200
Replacement Parts for Service and Repair
200
Tab. 103 Consumable Engine Parts
200
Tab. 104 Replacement Parts, Combination Filter
200
Tab. 105 Replacement Parts, Fresh Air Filter
200
12 Decommissioning, Storage and Transport
265
Decommissioning
265
Temporary Decommissioning
265
Tab. 106 "Temporarily Decommissioned" Information Notice
265
Long-Term Decommissioning and Storage
266
Tab. 107 Long-Term Decommissioning and Storage Checklist
266
Transport
267
Safety
267
Transporting the Machine as Trailer
267
Transporting the Machine by Crane
267
Tab. 108 Text for the Long-Term Decommissioned and Storage Information Notice
267
Transporting the Machine by Forklift
269
Transporting the Machine as Load
269
Fig. 81 Transporting Using a Forklift Truck
269
Fig. 82 Bracing to Secure the Load
270
Storage
271
Disposal
272
Removing the Batteries
272
Draining Operating Fluids
273
Draining Condensate
273
Fig. 83 Battery Labelling
273
Tab. 109 Machine Fluids
273
Tab. 110 Machine Option Fluids
273
Removing Filters/Filter Elements
274
Disposing of the Machine
274
Tab. 111 Machine Filters/Filter Elements
274
Tab. 112 Machine Option Filters/Filter Elements
274
13 Annex
275
Identification
275
Pipeline and Instrument Flow Diagram (P+I Diagram)
275
Fig. 84 Identification
275
Dimensional Drawings
280
Dimensional Drawing - Chassis
280
Dimensional Drawing, Chassis Options
282
Dimensional Drawing, Chassis Options
284
Dimensional Drawing, Chassis Options
286
Dimensional Drawing, Stationary Version
288
Dimensional Drawing, Stationary Version
290
Wiring Diagrams
292
Electrical Diagram
292
Lighting and Signaling System Connection
320
Lighting and Signaling System Connection
328
Generator Electrical Diagram, 400V, 3-Ph
333
Generator Electrical Diagram, 230V, 3-Ph
342
Generator Electrical Diagram, 115 V, 2-Ph
351
Battery Charger Electrical Diagram
360
Fuel Circulation Diagram
364
Compressed Air Flow Rate in Generator Mode
367
Operating Instructions for Compressed Air Filter (Combination Filter)
369
Operating Instructions for Compressed Air Filter (Fresh Air Filter)
397
Maintenance Tasks for the Generator
411
Oil-Injected MOBILAIR Service Intervals
411
Tab. 113 Service Maintenance Package - (1X Service Per Year)
411
Tab. 114 Service Intervals for MOBILAIR Parts, Filter SET Group (Compressor and Engine)
412
Tab. 115 Service Intervals for MOBILAIR Parts, Compressor Group
414
Tab. 116 Service Intervals for MOBILAIR Parts, Filter SET Group Engine
415
Tab. 117 Service Intervals for MOBILAIR Parts, Engine Group
417

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KAESER KOMPRESSOREN SIGMA CONTROL SMART MOBILAIR M82 Manual (418 pages)

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