KAESER Premium Compact W 200/4 Manuale utente
Service Manual
Reciprocating compressor
Premium compact W
No.: 9_9418 20E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/PPWCO 2.00 en SBA-PREMIUM COMPACT-TRAGBAR
20120822 115136
1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Weight .............................................................................................................................. 4
2.3 Compressor block ............................................................................................................ 4
2.4 Ambient conditions ........................................................................................................... 5
2.5 Pressure switch setting .................................................................................................... 5
2.6 Pressure ........................................................................................................................... 5
2.7 Sound emission ................................................................................................................ 5
2.8 Motor power and speed ................................................................................................... 6
2.9 Compressor oil recommendations ................................................................................... 6
2.9.1 Compressor oil charge ........................................................................................ 7
2.10 Power Supply ................................................................................................................... 7
2.10.1 Single phase ....................................................................................................... 7
2.11 Mains conditions .............................................................................................................. 9
2.11.1 Mains conditions at 230V/1/50Hz ....................................................................... 10
2.12 Machine duty cycle ........................................................................................................... 10
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 11
3.2 Specified Use ................................................................................................................... 11
3.3 Improper use .................................................................................................................... 11
3.4 User's Responsibilities ..................................................................................................... 12
3.4.1 Observe statutory and universally accepted regulations. ................................... 12
3.4.2 Qualified personnel ............................................................................................. 12
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 12
3.5 Dangers ............................................................................................................................ 13
3.5.1 Safely dealing with sources of danger ................................................................ 14
3.5.2 Safe machine operation ...................................................................................... 15
3.5.3 Organisational Measures .................................................................................... 17
3.6 Safety Devices ................................................................................................................. 17
3.7 Safety signs ...................................................................................................................... 17
3.8 Information signs .............................................................................................................. 18
3.9 In emergency ................................................................................................................... 19
3.9.1 Correct fire fighting ............................................................................................. 19
3.9.2 Treating injuries from handling cooling oil .......................................................... 19
3.10 Warranty ........................................................................................................................... 20
3.11 Environment protection .................................................................................................... 20
4 Design and Function
4.1 Machine function .............................................................................................................. 21
4.2 Operating modes and control modes ............................................................................... 22
4.2.1 Operating modes ................................................................................................ 22
4.2.2 Control modes .................................................................................................... 22
4.3 Safety devices .................................................................................................................. 22
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 23
Contents
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W i
5.2 Installation conditions ....................................................................................................... 23
6 Installation
6.1 Ensuring safety ................................................................................................................ 24
6.2 Reporting Transport Damage ........................................................................................... 24
6.3 Compressed air connection ............................................................................................. 25
6.4 Connecting the machine to the power supply .................................................................. 25
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 26
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 27
7.3 Checking installation and operating conditions ................................................................ 27
7.4 Motor overload protection ................................................................................................ 27
7.4.1 Resetting the motor overload protection switch for single-phase motors ........... 28
7.5 Measuring the air receiver charging time ......................................................................... 28
7.6 Setting the network pressure ........................................................................................... 28
7.7 Setting the pressure regulator .......................................................................................... 30
8 Operation
8.1 Switching on and off ......................................................................................................... 31
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 32
9.2 Alarms .............................................................................................................................. 32
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 34
10.2 Maintenance Schedule ..................................................................................................... 35
10.2.1 Logging maintenance work ................................................................................. 35
10.2.2 Regular maintenance tasks ................................................................................ 35
10.2.3 Oil change interval .............................................................................................. 35
10.2.4 Regular service tasks ......................................................................................... 36
10.3 Fan cowl maintenance ..................................................................................................... 36
10.3.1 Cleaning the fan cowl ......................................................................................... 36
10.4 Air filter maintenance ....................................................................................................... 37
10.5 Drive motor maintenance ................................................................................................. 37
10.6 Checking the oil level ....................................................................................................... 38
10.7 Topping up the compressor oil ......................................................................................... 38
10.8 Changing the compressor oil ........................................................................................... 39
10.9 Pressure relief valve checking ......................................................................................... 40
10.9.1 Air receiver pressure relief valve ........................................................................ 40
10.10 Air receiver maintenance ................................................................................................. 41
10.11 Venting the machine (de-pressurising) ............................................................................ 42
10.12 Maintaining the check valve ............................................................................................. 43
10.13 Maintenance of the pressure switch unloading valve ....................................................... 44
10.14 Cylinder head and valves ................................................................................................. 45
10.15 Documenting maintenance and service work .................................................................. 46
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 47
11.2 Ordering consumable parts and operating fluids/materials .............................................. 47
11.3 KAESER AIR SERVICE .................................................................................................. 47
11.4 Service Addresses ........................................................................................................... 48
11.5 Spares for service and repair ........................................................................................... 48
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 49
12.2 Packing ............................................................................................................................ 49
Contents
ii
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E
12.3 Storage ............................................................................................................................. 50
12.4 Transporting ..................................................................................................................... 50
12.4.1 Safety .................................................................................................................. 50
12.5 Disposal ........................................................................................................................... 50
13 Annex
13.1 Dimensional Drawing ....................................................................................................... 51
13.2 Electrical Diagram ............................................................................................................ 53
Contents
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W iii
Contents
iv
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E
Fig. 1 Location of safety signs .............................................................................................................. 18
Fig. 2 Machine layout ........................................................................................................................... 21
Fig. 3 Compressed air connection ........................................................................................................ 25
Fig. 4 Motor overload protection switch ................................................................................................ 28
Fig. 5 Setting the network pressure ...................................................................................................... 29
Fig. 6 Setting the pressure regulator .................................................................................................... 30
Fig. 7 Switching on and off ................................................................................................................... 31
Fig. 8 Cleaning the fan cowl ................................................................................................................. 36
Fig. 9 Air filter maintenance .................................................................................................................. 37
Fig. 10 Checking the oil level ................................................................................................................. 38
Fig. 11 Topping up the compressor oil ................................................................................................... 39
Fig. 12 Changing the compressor oil ...................................................................................................... 40
Fig. 13 Checking pressure relief valve on the air receiver ..................................................................... 41
Fig. 14 Draining condensate .................................................................................................................. 42
Fig. 15 Venting the machine .................................................................................................................. 42
Fig. 16 Cleaning the check valve ........................................................................................................... 43
Fig. 17 Maintenance of the pressure switch unloading valve ................................................................. 44
Fig. 18 Consumable parts ...................................................................................................................... 47
List of Illustrations
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W v
List of Illustrations
vi
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E
Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Weight ........................................................................................................................................ 4
Tab. 5 Compressor block ...................................................................................................................... 4
Tab. 6 Ambient conditions ..................................................................................................................... 5
Tab. 7 Pressure switch setting .............................................................................................................. 5
Tab. 8 Pressure specifications .............................................................................................................. 5
Tab. 9 Sound pressure level .................................................................................................................. 6
Tab. 10 Power and speeds ...................................................................................................................... 6
Tab. 11 Permissible starting frequency ................................................................................................... 6
Tab. 12 Compressor oil recommendations .............................................................................................. 7
Tab. 13 Compressor oil charge ............................................................................................................... 7
Tab. 14 Mains supply 110V/1/50Hz ......................................................................................................... 8
Tab. 15 Mains supply 230V/1/50Hz ......................................................................................................... 8
Tab. 16 Mains supply 110V/1/60Hz ......................................................................................................... 8
Tab. 17 Mains supply 115V/1/60Hz ......................................................................................................... 9
Tab. 18 Mains supply 127V/1/60Hz ......................................................................................................... 9
Tab. 19 Mains supply 220V/1/60Hz ......................................................................................................... 9
Tab. 20 Mains supply 230V/1/60Hz ......................................................................................................... 9
Tab. 21 Network impedance .................................................................................................................... 10
Tab. 22 Machine duty cycle ..................................................................................................................... 10
Tab. 23 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 13
Tab. 24 Safety signs ................................................................................................................................ 18
Tab. 25 Information signs ........................................................................................................................ 18
Tab. 26 Re-commissioning after storage ................................................................................................. 27
Tab. 27 Checklist of installation conditions .............................................................................................. 27
Tab. 28 Air receiver charging time ........................................................................................................... 28
Tab. 29 Changing the pressure switch setting ........................................................................................ 29
Tab. 30 Alarms and remedies ................................................................................................................. 32
Tab. 31 Regular maintenance tasks ........................................................................................................ 35
Tab. 32 Oil change intervals .................................................................................................................... 35
Tab. 33 Regular service tasks ................................................................................................................. 36
Tab. 34 Logged maintenance tasks ........................................................................................................ 46
Tab. 35 Consumable parts ...................................................................................................................... 47
List of Tables
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W vii
List of Tables
viii
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E
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