KAESER KOMPRESSOREN EPC-2-G Series Page 13 Assembly And Operating Manual Download

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2 Technical Specification

2.1 Nameplate

The machine's nameplate provides the model designation and important technical information.
➤ Enter here the nameplate data as a reference:

Feature

Value

Reciprocating Compressor
Part No.
Serial No.
Year of manufacture
Maximum working pressure
Delivery
Rated voltage
Synchronous speed
Rated power
Ambient temperature

Tab. 2 Nameplate

2.2 Options

The table contains a list of possible options.
➤ Enter options here as a reference.

Option

Option code

Available?

Oil level monitor

Adjustable machine mountings

Silenced air filter

Air filter with plastic casing

H10

Castors

H14

Bolt-on machine mounts for mounting on tank

H20

Tab. 3 Options

2.3 Weight

The weight indicated is the maximum weight. The actual weight depends on equipment fitted.

Model

Weight [kg]

EPC 150-2-G

40/-*

EPC 230-2-G

45/100*

* Machine with sound enclosure

Technical Specification

2.1

Nameplate

No.: 9_5753_04 E

Assembly and operating manual 2-stage piston compressor
EPC-2-G

Summary of Contents for EPC-2-G Series

Page 1: ...mbly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E Manufacturer KAESER KOMPRESSOREN GmbH 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 PEPC 1 04 en SBA KOLBEN AGGREGAT 2 STUFIG ...

Page 3: ...1 Basic Information 14 3 2 Specified Use 14 3 3 Improper use 14 3 4 User s responsibilities 14 3 4 1 Observe statutory and universally accepted regulations 14 3 4 2 Defining personnel 15 3 4 3 Inspection Schedules and Accident Prevention Regulations 15 3 5 Dangers 16 3 5 1 Safely dealing with sources of danger 16 3 5 2 Safe machine operation 18 3 5 3 Organisational Measures 18 3 5 4 Danger Areas 1...

Page 4: ...g 35 6 7 2 Anchoring the Machine 38 6 7 3 Mounting the machine on a compressed air tank 38 6 8 Retrofitting the Sound Enclosure accessory 39 6 8 1 Dismantling the sound enclosure 39 6 8 2 Vent the machine depressurize 39 6 8 3 Fitting the Sound Enclosure 40 7 Initial Start up 7 1 Safety 41 7 2 Instructions to be observed before commissioning or recommissioning 41 7 3 Checking installation and oper...

Page 5: ...anging the solenoid valve 61 10 14 Cylinder head and valves 61 10 14 1 Checking the cylinder head and valves 61 10 14 2 Cleaning the cylinder head and valves 62 10 14 3 Starting the machine and carrying out a trial run 62 10 15 Document maintenance and service work 63 11 Spares Operating Materials Service 11 1 Note the Nameplate 64 11 2 Ordering consumable parts and operating fluids materials 64 1...

Page 6: ...Contents iv Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 7: ...e mounts 38 Fig 17 Securing the bolt on machine mounts 38 Fig 18 Removing the air filter 39 Fig 19 Fitting the Sound Enclosure 40 Fig 20 Switching on and off 45 Fig 21 Cleaning the air cooler or fan guard 52 Fig 22 Air filter maintenance 53 Fig 23 Air Filter noise absorbing Maintenance 54 Fig 24 Air filter with plastic casing 55 Fig 25 Checking the oil level 56 Fig 26 Changing the compressor oil 5...

Page 8: ...List of Illustrations vi Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 9: ...pply details 690V 3 50Hz 9 Tab 20 Supply details 230V 3 60Hz 10 Tab 21 Supply details 380V 3 60Hz 10 Tab 22 Supply details 440V 3 60Hz 11 Tab 23 Supply details 460V 3 60Hz 11 Tab 24 Connection details for oil level monitoring 11 Tab 25 Network impedance 12 Tab 26 Machine duty cycle 12 Tab 27 Inspection intervals according to Ordinance on Industrial Safety and Health 15 Tab 28 Danger Areas 19 Tab 2...

Page 10: ...List of Tables viii Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 11: ...ble directives Missing documents can be requested from KAESER Make sure all documents are complete and observe the instructions contained in them Make sure you provide the data from the nameplate when ordering documents 1 3 Copyright This service manual is copyright protected Queries regarding use or duplication of the documentation should be referred to KAESER Correct use of information will be f...

Page 12: ...o avoid dangerous situations This symbol is is placed by lists of actions comprising one stage of a task In lists of actions with several stages the sequence of actions is numbered This symbol is is placed by lists of actions comprising one stage of a task In lists of actions with several stages the sequence of actions is numbered Information that refers to only one option is marked with an indica...

Page 13: ...ble contains a list of possible options Enter options here as a reference Option Option code Available Oil level monitor C5 Adjustable machine mountings H1 Silenced air filter H9 Air filter with plastic casing H10 Castors H14 Bolt on machine mounts for mounting on tank H20 Tab 3 Options 2 3 Weight The weight indicated is the maximum weight The actual weight depends on equipment fitted Model Weight...

Page 14: ...ns Installation Maximum altitude AMSL m 1000 Permissible ambient tem perature C 5 35 Higher altitudes are permissible only after consultation with the manufacturer Tab 6 Ambient Conditions 2 6 Ventilation The values given are minimum guide values Model Inlet aperture Z m2 Exhaust fan A m3 h EPC 150 2 G 0 4 330 EPC 230 2 G 0 4 510 EPC 420 2 G 0 4 900 EPC 550 2 G 0 4 1200 EPC 750 2 G 0 5 1650 Forced...

Page 15: ...pressure of the cylinder relief valve EPC 420 2 bis EPC 1000 2 Activating pressure of the air cooler relief valve EPC 420 2 bis EPC 1000 2 Maximum working pres sure bar 15 Activating pressure bar 17 5 Tab 10 Activating pressure of the air cooler relief valve EPC 420 2 bis EPC 1000 2 2 8 Sound Pressure Level Operational state Operating mode LOAD at rated speed rated air flow and nominal pressure Me...

Page 16: ...5 1500 1800 Tab 12 Power and speed Permissible starting frequency Read off the permissible starting frequency of the motor from the table below Rated power kW Permissible starting frequency 1 h 1 1 20 1 7 20 3 0 15 4 0 15 5 5 15 7 5 15 Tab 13 Permissible starting frequency 2 10 Compressor oil recommendations The standard compressor oil is SAE 5 W30 or VDL 150 For special applications FGPor S 150 c...

Page 17: ...ressor Cool to moderate ambient temperatures low humidity low to average duty cycle Tab 14 Compressor oil recommendations 2 10 1 Compressor oil charge Model Total charge litres Topping up volume litres minimum maximum KC 150 2 1 1 0 1 KC 236 2 1 1 0 1 KC 420 2 1 2 0 2 KC 550 2 1 2 0 2 KC 750 2 1 5 0 4 KC 1000 2 1 5 0 4 Tab 15 Compressor oil charge 2 11 Power Supply Basic requirements The machine i...

Page 18: ...43 and IEC 60364 4 473 and DIN VDE 0298 4 standards for 30 C ambient temperature and wiring type C For other application conditions check conductor diameters and change accordingly Cables laid side by side must be separated by a distance equal to one cable diameter Other conditions would include for example Higher temperature Other cable installation method Cable length 50 m Bundled cables Mains f...

Page 19: ...ly cable mm2 Backup fuse A Supply cable mm2 150 2 G 2 2 6 4 x 1 5 230 2 G 3 2 10 4 x 1 5 6 4 x 1 5 420 2 G 5 2 10 4 x 1 5 6 4 x 1 5 550 2 G 8 0 16 4 x 2 5 10 4 x 1 5 750 2 G 9 6 20 4 x 2 5 10 4 x 1 5 1000 2 G 14 4 35 4 x 6 16 4 x 2 5 Pressure switch Controller star delta Tab 18 Supply details 500V 3 50Hz Rated voltage 690V 10 3 50Hz Direct online starting Star delta starting EPC type Current input...

Page 20: ...17 4 35 4 x 6 20 4 x 2 5 750 2 G 21 0 50 4 x 10 25 4 x 4 1000 2 G 28 0 63 4 x 16 35 4 x 6 Pressure switch Controller star delta Tab 20 Supply details 230V 3 60Hz Rated voltage 380V 10 3 60Hz Direct online starting Star delta starting EPC type Current input A Backup fuse A Supply cable mm2 Backup fuse A Supply cable mm2 150 2 G 2 8 6 4 x 1 5 230 2 G 4 2 10 4 x 1 5 420 2 G 7 1 16 4 x 2 5 10 4 x 1 5 ...

Page 21: ...ly cable mm2 Backup fuse A Supply cable mm2 150 2 G 2 3 6 4 x 1 5 230 2 G 3 5 6 4 x 1 5 420 2 G 5 9 16 4 x 2 5 10 4 x 1 5 550 2 G 8 7 16 4 x 2 5 10 4 x 1 5 750 2 G 10 5 25 4 x 4 16 4 x 2 5 1000 2 G 15 5 35 4 x 6 20 4 x 2 5 Pressure switch Controller star delta Tab 23 Supply details 460V 3 60Hz 2 11 2 Option C5 Electrical connection details for oil level monitoring Characteristic Value Contact load...

Page 22: ...C 420 2 Direct online 15 0 099 Star delta 0 366 EPC 550 2 Direct online 15 0 077 Star delta 0 280 EPC 750 2 Direct online 15 0 048 Star delta 0 178 EPC 1000 2 Direct online 15 0 029 Star delta 0 104 Tab 25 Network impedance 2 13 Machine duty cycle Calculating the cycling period Cycling time time under load time at standstill Calculating the duty cycle Duty cycle time under load time under load sta...

Page 23: ... 230 2 G 70 3 30 EPC 420 2 G 70 4 30 EPC 550 2 G 70 4 30 EPC 750 2 G 70 4 30 EPC 1000 2 G 70 4 30 Tab 26 Machine duty cycle 2 Technical Specification 2 13 Machine duty cycle No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 13 ...

Page 24: ...is service manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated Do not use compressed for any application that will bring it into direct contact with foodstuffs unless it is specifically treated 3 3 Improper use Never direct compressed air at persons or animals Us...

Page 25: ...ve received adequate training in and authorization for the safe installation and mainte nance of this machine Ensure that personnel entrusted with operation installation and maintenance are qualified and authorized to carry out their tasks 3 4 3 Inspection Schedules and Accident Prevention Regulations The machine is subject to local inspection schedules Examples of German inspection schedules Recu...

Page 26: ... machine power Check regularly that all electrical connections are tight and in proper condition Forces of compression Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following information concerns work on components that could be under pressure Close shut off valves or otherwise isolate the machine from the distribution network to ensur...

Page 27: ...nsulation Use hearing protection when appropriate The pressure relief valve blowing off can be particularly loud Operating fluids materials Strictly forbid fire open flame and smoking Follow safety regulations when dealing with oils lubricants and chemical substances Avoid contact with skin and eyes Do not inhale oil mist and vapours Do not eat or drink while handling cooling and lubricating fluid...

Page 28: ...c requirements with regard to explosion protection are in force For instance the requirements of ATEX directive 94 9 EC Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres Ensure adequate ventilation Ensure that required ambient conditions are maintained with regard to Ambient temperature and humidity Clean inlet air with no damaging contaminants Inlet air free o...

Page 29: ... a 1 m radius of the machine Operating personnel Maintenance Within the machine Within a 1 m radius of the machine Maintenance personnel Tab 28 Danger Areas 3 6 Safety Devices Various safety devices ensure safe working with the machine Do not change bypass or disable safety devices Check safety devices for correct function regularly Do not remove or obliterate labels and notices Ensure that labels...

Page 30: ...ce Wear long sleeved garments not synthetics such as polyester and protective gloves Tab 29 Safety Signs 3 8 Information signs The table lists the various information signs used and their meanings Symbol Meaning Take heed of safety instructions and the service manual Maintain the air filter regularly Check the oil level regularly and change the oil at the correct intervals Tab 30 Information signs...

Page 31: ... general terms and condi tions 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 intended under the conditions specified 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 oblig...

Page 32: ... This applies particularly to parts contaminated with compressor oil Drain condensate into a receptacle Obtain advice from KAESER on suitable drains and receptacles Do not allow operating materials to escape to the environment or into the sewage system 3 Safety and Responsibility 3 11 Environmental Protection 22 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 33: ... 1 Air filter 2 Compressor block 3 Electric motor 4 Compressed air cooler 5 Cylinder relief valve 6 Oil filler port 7 Oil sight glass 8 Oil drain plug 9 Arrow showing direction of rotation 10 Compressed air outlet 11 Air cooler relief valve 12 Solenoid valve 4 Design and Function 4 1 Outline of the machine No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 23 ...

Page 34: ... pipe or cooler to the compressed air outlet 4 2 Options The options available for your machine are described below 4 2 1 Option C5 Oil level monitoring The oil level in the machine is monitored automatically The machine is automatically shut down if the oil level falls below minimum Fig 4 Oil level monitoring 1 Oil level monitoring 4 2 2 Option H1 Adjustable machine mountings These mounts allow t...

Page 35: ...level of the machine It also cleans the inlet air Fig 6 Silenced air filter 1 Air filter element 4 2 4 Option H10 Air filter with plastic casing This air filter is suitable for unfavourable ambient conditions It also cleans the inlet air 4 Design and Function 4 2 Options No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 25 ...

Page 36: ...ine Fig 8 Castors 1 Castors 2 Wheel stops 4 2 6 Option H20 Bolt on machine mounts for mounting on tank For the vibration free and quiet installation of the machine on e g a compressed air tank 4 Design and Function 4 2 Options 26 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 37: ...olenoid valve and the oil level monitoring Option C5 This enables an unloaded starting of the machine The control unit is not provided with the machine and is to be supplied by the user The following points have to be observed Install the control unit to EN 60204 specifications Select the components to suit the motor power Connect the solenoid valve such that it first closes when the drive motor h...

Page 38: ...r overload protection The motor protection device shuts down the machine in the case of a phase drop out overload if the ambient temperature becomes too high if the compressor block seizes if the mains voltage fluctuates outside limits AC motors may be operated only with correctly set motor protection switch or overload relay The warranty is void without motor protection Further information See ch...

Page 39: ...ained with regard to ambient temperature and humidity clean inlet air with no damaging contaminants inlet air free of explosive or chemically unstable gases or vapours inlet air free of acid alkaline forming substances particularly ammonia chlorine or hydrogen sulphide Keep suitable fire extinguishing agents ready for use 5 2 Installation conditions 5 2 1 Determining location and clearances The cl...

Page 40: ...t without danger or hindrance 5 2 2 Ensuring adequate ventilation If the ventilation is insufficient a partial vacuum can be created in the room 1 Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine and exhaust fan 2 Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually open 3 Keep...

Page 41: ...ed air network the network working pressure may not exceed the permissible working pressure of the machine Please contact KAESER for advice 5 Installation and Operating Conditions 5 2 Installation conditions No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 31 ...

Page 42: ...pressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 The pressure gauge on the machine must read 0 bar Working on the drive system 1 Switch off and lock out the power supply disconnecting device and check that no voltage is present 2 Replace and secure all enclosure panels before starting the machine Further ...

Page 43: ...essed air connection 1 Flexible hose 2 Shut off valve 3 Check valve A shut off valve and check valve must be installed by the user in the connection line Make the connection to the air main by a flexible hose 6 5 Typical installation for safety and regulating devices The following example does not refer to an actual application Safety and regulating devices ensure a safe machine operation 6 Instal...

Page 44: ...upply Precondition The machine is disconnected from all power supply phases The disconnecting device is locked in the off position A check has been made that no voltage is present 1 Have the power supply connected only by authorized installation personnel or an authorized electrician 2 Carry out safety measures as stipulated in relevant regulations IEC 364 for example or DIN VDE 0100 and in nation...

Page 45: ... disconnecting device and check that no voltage is present 6 Connect the machine to the power supply 6 7 Options The options available for your machine are described below 6 7 1 Option C5 Oil level monitoring The oil level monitor does not relieve the user of the obligation to visually check the oil level at regular intervals The contact in the oil level monitor is wired at the factory as a normal...

Page 46: ...vel 1 The user is to make the connection to the power supply or the connection to an external control unit 2 The machine is switched off by the external controller 6 7 1 1 Float switch The float switch has been set at the factory as follows The machine shuts down when the oil falls to its minimum permissible level The tip of the red arrow is visible for 2 mm Check the setting and adjust if require...

Page 47: ...of fatal injury caused by contact with live components Switch off and lock out the power supply disconnecting device and verify the absence of voltage 2 Open the switch cover 3 Loosen the screw and move the sensing contact 4 Re tighten the screw 5 Close the cover until it latches 6 Switch on the machine 6 Installation 6 7 Options No 9_5753_04 E Assembly and operating manual 2 stage piston compress...

Page 48: ...wing in chapter 13 2 6 7 3 Option H20 Mounting the machine on a compressed air tank Fig 17 Securing the bolt on machine mounts 1 Bolt on machine foot 2 Threaded joint 3 Hex head bolt 4 Hexagon nut Use appropriate fixing bolts to anchor the machine Further information Details of the anchoring threads are shown in the dimensional drawing in chapter 13 2 6 Installation 6 7 Options 38 Assembly and ope...

Page 49: ...d in the off position A check has been made that no voltage is present The machine is completely depressurised pressure gauge reads 0 bar The machine has cooled down The user s shut off valve between the machine and the air network is closed Fig 18 Removing the air filter 1 Compressor block 2 Hexagonal nut 3 Machine mounting pad 4 Bracket 5 Air filter 6 Hexagonal nut DANGER Dangerous voltage There...

Page 50: ... Fitting the Sound Enclosure 1 Compressor block 2 Base plate 3 Machine mounting pad 4 Air cooler 5 Hose 6 User s check valve 7 Sheet metal ring 8 Pre cut foam 9 Air inlet soundproofing box 10 Sound enclosure 11 Snap fastener 12 Panel exhaust louver 1 Set the machine on the base plate and secure the machine mountings 2 Fix the sheet metal ring to the cooler with the fixings provided and slide the f...

Page 51: ...Working on pressure systems 1 Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 The pressure gauge on the machine must read 0 bar Working on the drive system 1 Switch off and lock out the power supply disconnecting device and check that no ...

Page 52: ...e specifications on the nameplate 2 1 Are the power supply cable conductor diameters and fuse ratings ad equate 2 11 Have all electrical connections been checked for tightness Repeat check after 50 operating hours Are the user s shut off and check valves fitted to the compressed air outlet 6 4 Is the connection to the air main made with a flexible hose 6 4 Sufficient oil in the crankcase oil in th...

Page 53: ...e motor overload protection device This phase current is 0 58 times the rated motor current see motor nameplate The overload protection device setting can be 10 higher than the rated phase current to prevent it from being triggered by voltage fluc tuations temperature influences or compo nent tolerances 1 Switch the machine on from the external con trol unit Was the machine shut down by the motor ...

Page 54: ...time the compressor takes to fill the air receiver when new can be useful in checking the machine s performance at a later date Precondition Machine at operating temperature 1 Close the shut off valve to the air main 2 Switch on the power supply disconnecting device 3 Measure the air receiver charging time 4 Enter the charging time the receiver size and machine model in the table Machine model Air...

Page 55: ...ous injury is possible The machine restarts automatically when power is restored after a power cut Make sure that no one is working on the machine Switch the machine on and off according to the start configuration 8 1 1 Direct online starting Precondition A power supply disconnecting device has been installed by the user No personnel are working on the machine All panels are in place and secured T...

Page 56: ...Switch on the machine from the external control unit Result The machine starts as soon as network pressure is lower than the cut out pressure Switching off 1 Switch off the machine from the external control unit 2 Switch off and lock out the power supply isolating device 8 1 3 Star delta starting Precondition The user has connected a control unit A power supply isolating device has been installed ...

Page 57: ...the cut out pressure Switching off 1 Switch off the machine from the external control unit 2 Switch off and lock out the power supply isolating device 8 Operation 8 1 Switching on and off No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 47 ...

Page 58: ...ge trip in the user s pressure switch or the controller Machine starts with difficulty The solenoid valve is not open ing Check the connection to the sol enoid valve Change the solenoid valve Bearing damage Contact KAESERservice Piston seized due to insufficient or incorrect oil Contact KAESERservice Fault in the power supply Check power supply Oil level too high Drain out some oil Machine runs ho...

Page 59: ...e user s pres sure switch while the machine is running Defective switch diaphragm Replace the pressure switch The venting valve is not closing Clean or replace the venting valve Whistling sound from the cylin der head Remove the screws Gasket de fective Tighten screws Replace gasket The pressure relief valve blows off before the cut out pressure is reached Pressure switch incorrectly set Check pre...

Page 60: ...r can flow back into the machine 2 Vent all pressurized components and chambers completely Working on the drive system 1 Switch off and lock out the power supply disconnecting device and check that no voltage is present 2 Replace and secure all enclosure panels before starting the machine Further information See chapter 3 4 2 regarding authorized personnel See chapter 3 5 regarding dangers and the...

Page 61: ... Regular maintenance tasks 10 2 3 Oil change interval Duty cycles and ambient conditions are important criteria for the number and length of the oil change intervals Advice can be obtained from KAESER Service on determining suitable changing intervals Check operating conditions and adjust intervals as necessary log the results in table 37 for future reference Maximum permissible oil change interva...

Page 62: ...0 3 Maintaining the air cooler or fan guard According to machine model it either has an air cooler of a fan guard Clogging causes overheating and machine damage Regular cleaning ensures reliable cooling of the machine and the compressed air The frequency is mainly dependent on local operating conditions Material Brush Vacuum cleaner Face mask as required Precondition The supply disconnecting devic...

Page 63: ...ice is switched off the device is locked off a check has been made that no voltage is present The machine has cooled down Fig 22 Air filter maintenance 1 Air filter 2 Inlet air opening 3 Air filter element 4 Retaining clip 5 Cover 1 Unscrew the air filter 2 Release the retaining clip and take off the cover 3 Blow out the cover and the insert with dry compressed air 5 bar 4 Clean the housing and se...

Page 64: ...t dirt to ingress the pressure system and cause damage to the machine Material Compressed air for blowing out Spares as required Precondition The 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 Fig 23 Air Filter noise absorbing Maintenance 1 Air filter element 2 Inlet air opening 3 Retaining clip 4 Co...

Page 65: ...he housing and sealing faces 5 Replace the filter element 6 Position the cover and close the retaining clips 7 Switch on the power supply disconnecting device 10 6 Option H10 Air filter with plastic casing Check that all sealing surfaces match each other The use of an unsuitable air filter element can permit dirt to ingress the pressure system and cause damage to the machine Material Compressed ai...

Page 66: ... the housing and sealing faces 5 Replace the filter element 6 Replace the cover and screw down tight 7 Switch on the power supply disconnecting device 10 7 Drive Motor Maintenance The drive motor bearings are permanently greased and need no re greasing Have the motor bearings checked during service 10 8 Checking the oil level The oil level can be read off on the oil sight glass Precondition The ma...

Page 67: ...ff the machine and check visually for leaks 10 10 Changing the compressor oil The initial charge of oil should be changed as specified in table 36 Drain the oil completely from the compressor block If oil level monitoring is fitted check its function as detailed in chapter 6 7 1 Change the oil immediately if it becomes milky This indicates a high condensate content Contact KAESER Service if conden...

Page 68: ... machine and check the oil level again after about 2 minutes topping up again if nec essary 4 Switch off the machine and check visually for leaks 10 11 Testing the pressure relief valve To check the valve activating pressure it must be removed from the machine by a KAESER Service Technician and installed in a test rig Further information See chapter 2 7 for the activating pressure of the valve 10 ...

Page 69: ...ure relief valve anticlockwise until air blows off 2 Then turn the knurled knob back to its original position Pressure relief valve does not blow off Have the defective relief valve replaced by KAESER Service 10 12 Venting the machine de pressurising Even when switched off the machine is still under pressure from the air main to the user s check valve The machine must be fully disconnected from co...

Page 70: ...system Material Compressed air for blowing out Cleaning rags Acid free grease e g Shell Retinax Replacement part Precondition The mains disconnecting device is switched off The disconnecting device is locked in the off position A check has been made that no voltage is present Machine is fully vented no pressure The user s shut off valve between the machine and the air network is closed 10 13 1 Cle...

Page 71: ...on is correct as indicated by the arrow on the body 4 Screw the fitting and damper into the new solenoid valve using sealing tape 5 Re install the solenoid valve in the compressed air line 6 Open the user s shut off valve between the machine and the air system 7 Start the machine and visually check for leaks 10 14 Cylinder head and valves Material Compressed air for blowing out Cleaning cloths Bru...

Page 72: ...ine and the air network is closed 1 Remove the cylinder head screws and lift off the head 2 Remove the cap nut if one is fitted 3 Clean the cylinder head and valves 4 After cleaning the cylinder head and valves mount the head with the gasket and tighten the screws diagonally Tightening torque for cylinder head screws Model Low pressure cylinder head screws MA Nm High pressure cylinder head screws ...

Page 73: ...ce and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 40 Logged maintenance tasks 10 Maintenance 10 15 Document maintenance and service work No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 63 ...

Page 74: ...rating fluids materials may damage the ma chine or impair its proper function Personal injury may result from machine damage Use only original KAESER parts and operating fluids materials Have an authorised KAESER Service Technician carry out regular maintenance Fig 30 Consumable parts 10 Air filter 20 Air filter element silenced 30 Air filter element plastic housing 40 Solenoid valve Machine Name ...

Page 75: ...ty as all regulations are kept to Why not sign a KAESER AIR SERVICE maintenance agreement Result Your advantage lower costs and higher compressed air availability 11 4 Service Addresses Addresses of KAESER agents are given at the end of this manual 11 5 Spare Parts for Service and Repair Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER...

Page 76: ...llow the machine to cool down completely 2 Spray the valves and cylinder bore with Shell Ensis 20 preserving oil The oil does not need to be removed when re commissioning 3 Disconnect all air and electrical connections 4 Spray all contacts and terminals with a preservative e g Rivalto W S X 12 2 Packing A wooden crate is required for overland transport to protect the machine from mechanical damage...

Page 77: ... or lifting gear with personnel trained in the safe transport of goods Make sure the danger zone is clear 12 4 2 Transporting with a forklift truck Precondition Machine must stand on a suitable transport medium pallet Fig 31 Transporting with a forklift truck Drive the forks completely under the palette and lift carefully 12 4 3 Transporting with a crane A suitable lifting frame ensures correct tr...

Page 78: ...12 5 Disposal When disposing of a machine drain out all liquids and remove dirty filters Precondition The machine is decommissioned 1 Completely drain the oil from the machine 2 Remove old filters 3 Hand the machine over to an authorized disposal expert Components contaminated with oil must be disposed of in accordance with local environ ment protection regulations 12 Decommissioning Storage and T...

Page 79: ...Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 69 ...

Page 80: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 70 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 81: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 71 ...

Page 82: ...13 2 Dimensional Drawing 13 Annex 13 2 Dimensional Drawing 72 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 83: ...13 Annex 13 2 Dimensional Drawing No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 73 ...

Page 84: ...13 Annex 13 2 Dimensional Drawing 74 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 85: ...13 Annex 13 2 Dimensional Drawing No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 75 ...

Page 86: ...13 3 Electrical diagram 13 Annex 13 3 Electrical diagram 76 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 87: ...13 Annex 13 3 Electrical diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 77 ...

Page 88: ...13 Annex 13 3 Electrical diagram 78 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 89: ...13 Annex 13 3 Electrical diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 79 ...

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Page 91: ...13 Annex 13 3 Electrical diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 81 ...

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Page 93: ...13 Annex 13 3 Electrical diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 83 ...

Page 94: ...13 Annex 13 3 Electrical diagram 84 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

Page 95: ...13 Annex 13 3 Electrical diagram No 9_5753_04 E Assembly and operating manual 2 stage piston compressor EPC 2 G 85 ...

Page 96: ...13 Annex 13 3 Electrical diagram 86 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753_04 E ...

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