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KAESER KCT blue T Series, Operator'S Manual

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KAESER KCT blue T Series Operator'S Manual Download Page 1

 

Operator manual 

Reciprocating compressor  

KCT blue T  

  

No.: 902350 00E

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com

Summary of Contents for KCT blue T Series

Page 1: ...Operator manual Reciprocating compressor KCT blue T No 902350 00E Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 www kaeser com...

Page 2: ...Original instructions KKW PDENT 2 10 en SBA DENTAL T ANLAGE 20190503 092636...

Page 3: ...afety and Responsibility 3 1 Basic instructions 12 3 2 Specified use 12 3 3 Improper use 12 3 4 User s responsibilities 13 3 4 1 Observe statutory and universally accepted regulations 13 3 4 2 Determi...

Page 4: ...ection for three phase motors 36 7 4 2 Resetting the motor overload protection switch for single phase motors 37 7 5 Checking direction of rotation 3 phase machines only 37 7 6 Starting the machine fo...

Page 5: ...54 12 2 Packing 54 12 3 Storage 54 12 4 Transport 55 12 4 1 Safety 55 12 4 2 Transporting with a forklift truck 55 12 5 Disposal 55 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 56 13...

Page 6: ...Contents iv Operator manual Reciprocating compressor KCT blue T No 902350 00E...

Page 7: ...on switch 37 Fig 9 Checking the direction of rotation 38 Fig 10 Switching on and off 39 Fig 11 Operating hours counter 40 Fig 12 Cleaning the air cooler or fan cowl 45 Fig 13 Air filter maintenance 46...

Page 8: ...List of Illustrations vi Operator manual Reciprocating compressor KCT blue T No 902350 00E...

Page 9: ...1 60Hz 9 Tab 16 Connection data 208 230V 1 60Hz 9 Tab 17 Supply details 400V 3 50Hz 10 Tab 18 Network impedance 10 Tab 19 Network impedance 11 Tab 20 Inspection intervals according to Ordinance on Ind...

Page 10: ...List of Tables viii Operator manual Reciprocating compressor KCT blue T No 902350 00E...

Page 11: ...ake sure you give the data from the nameplate when ordering documents 1 3 Copyright This operating manual is protected by copyright Any queries regarding the use or duplication of this documentation s...

Page 12: ...e shown here 2 Always read and comply with warning instructions 1 4 2 Potential damage warnings Contrary to the warnings shown above damage warnings do not indicate a potential personal in jury Warnin...

Page 13: ...uence of the operating steps Information relating to one option only are marked with an option code e g H1 indicates that this section applies only to machines with screw in machine feet Information r...

Page 14: ...le contains a list of possible options Option Available Operating hours counter Machine dependent only available with KCT blue 230 65 T Tab 4 Options 2 3 Weight The values shown are maximum values The...

Page 15: ...l min Tab 6 Compressor block 2 5 Ambient conditions Installation Maximum eleva tion AMSL 1 m 1000 Permissible ambient tem perature C 5 35 1 Higher altitudes are permissible only after consultation wi...

Page 16: ...r 7 91 Safety valve actuating pressure bar 8 0 10 01 1 KCT blue 230 65 T Tab 10 Pressure specifications 2 9 Noise emission dB A Compressor type Sound pressure level dB A KCT blue 110 24 T 65 521 KCT b...

Page 17: ...T blue 230 24 T KCT230 2 2 1500 1800 KCT blue 230 65 T KCT230 2 2 1500 1800 KCT blue 420 65 T KCT420 2 2 1500 1800 KCT blue 420 90 T 2x KCT420 2x 2 2 1500 1800 Tab 13 Power and speed Three phase curre...

Page 18: ...C without cable contact Current carrying capacity of conduits Table 3 Column 11 European Harmonisation Directive HD 60364 5 52 2011 Cable bundling Table 21 Single layer on wall or floor Spacing outsid...

Page 19: ...ed Connection to an IT supply is not permitted without taking further measures earth leak detection etc Further information When connecting to a European 400 V 3 50 Hz rated voltage the requirements i...

Page 20: ...z Rated voltage between exterior and neutral lines 220V 250V Rated voltage between the external lines 380V 430V They do not apply to private power supplies within industrial areas isolated from the pu...

Page 21: ...starts 1 1 h Highest permissible System impe dance2 Zmax KCT blue 110 24 T 20 KCT blue 230 24 T 20 0 257 KCT blue 230 65 T 20 0 257 KCT blue 420 65 T 20 0 257 KCT blue 420 90 T 20 0 194 1 Exceeding th...

Page 22: ...ine 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 air for any...

Page 23: ...ompressed air devices Authorised installation and maintenance personnel have the following qualifications are of legal age must have read be conversant with and adhere to the safety instructions and s...

Page 24: ...ation or the last inspection if PS x V 1000 Approved supervisory body Strength test Every 10 years after installation or the last inspection if PS x V 1000 Qualified persons e g KAESER SERVICE techni...

Page 25: ...that no compressed air can flow back into the machine Fully de pressurise all pressurised components and enclosures Do not carry out welding heat treatment or mechanical modifications to pressurised c...

Page 26: ...safety regulations when dealing with chemical substances Avoid contact with skin and eyes Do not breathe vapours Do not eat or drink while operating fluieds materials Keep suitable fire extinguishing...

Page 27: ...le lifting gear that conforms to local safety regulations Allow transportation only by personnel trained in the safe movement of loads Attach lifting gear only to suitable lifting points Be aware of t...

Page 28: ...n cause accidents with severe ad verse effects for your health Maintenance work should be carried out by authorised personnel only Wear close fitting flame resistant clothing Wear protective clothing...

Page 29: ...nstallation Within the machine Within 1 m radius of the machine and its sup ply cables Installation personnel Operation Within a 1 m radius of the machine Operating personnel Maintenance Within the ma...

Page 30: ...e 2 Hot surface Risk of burns caused by contact with hot components Do not touch the surface Wear long sleeved garments no synthetics such as polyester and pro tective gloves 3 Risk of injury caused b...

Page 31: ...achine Disconnect the machine from the energy supply Isolate the compressor from the air system Vent depressurise the machine completely Check for zero pressure Tab 22 Safety signs 3 8 Emergencies 3 8...

Page 32: ...thermore we do not assume any warranty obligation for damages caused by the use of unsuitable parts or operating materials arbitary modifications incorrect maintenance incorrect repair Correct mainten...

Page 33: ...sure switch 7 Compressor drive motor 8 Pressure gauge 9 Compressed air cooler 10 Condensate outlet 11 Compressed air outlet 12 Pneumatic venting valve 13 Timer module 14 Solenoid valve 15 Compressed a...

Page 34: ...ve 7 Compressed air 8 Regeneration air 9 Compressed air cooler Function of the compressed air dryer The compressed air temperature is reduced in the air cooler before it enters the compressed air drye...

Page 35: ...pacity of the compressor to regenerate the desiccant allows a short regen eration time and therefore high machine availability depending on the machine type up to 80 90 4 2 Operating points and contro...

Page 36: ...ately in an emergency situation The motor is stopped The pressure system is vented Safety valve The safety valve protects the system against impermissible pressure rise It is factory set Check valve T...

Page 37: ...cient and suitable lighting such that the display can be read and work carried out comfortably and safely Keep suitable fire extinguishing media ready for use Ensure that required ambient conditions a...

Page 38: ...r plant be directed to the cooling air inlet end of the compressor Hot air can cause damage to the machine 5 2 2 Ensuring the machine room ventilation Adequate ventilation of the machine room fulfils...

Page 39: ...he apertures constant airflow Ensure correct machine positioning all machines must be able to draw in cool fresh air Ensure that hot exhaust air leaves the room by the shortest direct path Do not exce...

Page 40: ...re is no voltage on potential free contacts When working on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The follo...

Page 41: ...lings to lift the machine Fig 5 Fitting the rubber pads 1 Rubber pad 2 Hexagonal nut Remove the wooden frame from the air receiver feet Screw the rubber pads to the receiver feet with hexagon nuts 6 4...

Page 42: ...the machine with a lockable power supply isolating device which must comply with the requirements of EN60204 1 2006 5 3 This could be for example a load disconnect switch with fused input If a circuit...

Page 43: ...y isolating device is switched off the device is locked off the absence of any voltage has been verified The machine is fully vented Verify the absence of pressure using a suitable measuring device pr...

Page 44: ...ge 3 Remove and disconnect the electric cable and pressure line from the machine 4 Position the rear panel 5 Attach the enclosure base to the rear panel 6 Note the motor size and position the machine...

Page 45: ...al free contacts When working on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following safety concerns relate...

Page 46: ...rk within the permissible tolerance limits of the rated voltage machine 13 3 Are the power supply cable conductor diameters and fuse ratings ade quate 2 11 Have all electrical connections been checked...

Page 47: ...value set on the motor overload protection switch Have the machine checked if the motor overload protection switch trips out frequently at short intervals Fig 8 Motor overload protection switch 1 Trip...

Page 48: ...he shut off valve to the air network 2 Switch on the power supply disconnecting device 3 Turn the ON OFF switch to the I position The machine switches to LOAD and delivers compressed air Watch for any...

Page 49: ...ree compressor Do not pour oil into the crankcase Auto Accumulating condensate is automatically drained Tab 25 Marking WARNING Automatic restart Serious injury is possible The machine restarts automat...

Page 50: ...than the cut out pressure Switching off 1 Turn the ON OFF switch to the 0 position 2 Switch off and lock out the power supply isolating device 8 2 Operating hours counter Maintenance intervals can be...

Page 51: ...rts with difficulty Venting valve defective Call KAESER SERVICE Bearing damage Call KAESER SERVICE Fault in the power supply Check power supply Machine runs hot Ambient temperature too high Reduce the...

Page 52: ...check valve The venting valve loses air while the machine is running The pressure builds up too slowly or not at all the venting valve is defective Call KAESER SERVICE Pressure does not build up the s...

Page 53: ...hat there is no voltage on potential free contacts When working on the compressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death Th...

Page 54: ...Carry out maintenance tasks in due time taking ambient and operating conditions into consid eration Interval Maintenance task See chapter Monthly Check the compressed air dryer for reliable operation...

Page 55: ...ks 10 3 Maintaining the air cooler or fan cowl Depending on the compressor model either an air cooler of a fan with a fan cowl has been installed Clogging causes overheating and machine damage Regular...

Page 56: ...econdition The power supply isolating device is switched off all poles the device is locked off the absence of any voltage has been verified The machine has cooled down Fig 13 Air filter maintenance 1...

Page 57: ...at 3 Replace the cover and screw down 10 6 Drive motor maintenance The drive motor bearings are permanently greased Re greasing is not necessary Have the motor bearings checked by an authorised KAESER...

Page 58: ...air receiver Since the machines are equipped with a compressed air dryer there is almost no condensate in the air receiver Fig 15 Condensate shut off valve 1 Condensate shut off valve Open the conden...

Page 59: ...pressed air can flow back into the machine Fig 16 Venting the machine 1 Condensate shut off valve 1 Close the user s shut off valve between the machine and the air distribution network 2 Open the cond...

Page 60: ...ger of burns from hot components Wear long sleeved clothing and gloves Work with caution 2 Remove the screw plug 3 Clean the valve seat and valve cone with a cleaning cloth and blow out with dry compr...

Page 61: ...tenance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 29 Logged maintenance tasks 10 Maintenance 10 12 Documenting maintenance and service wo...

Page 62: ...y result from damage Use only original parts and operating fluids materials Have an authorised KAESER SERVICE technician carry out regular maintenance Compressed air dryer Name Number Maintenance KIT...

Page 63: ...nce agreement Your advantage lower costs and higher compressed air availability 11 4 Replacement parts for service and repair Make sure that any service or repair tasks not described in this manual ar...

Page 64: ...e concerning sea or air transport Material Desiccant Plastic sheeting Rigid carton as transport packing Precondition The machine is decommissioned Machine is dry and cooled down 1 Wrap the machine in...

Page 65: ...vement of goods Ensure the danger area is clear of personnel 12 4 2 Transporting with a forklift truck Precondition The whole transport pallet is on the forks Fig 18 Transporting with a forklift truck...

Page 66: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 56 Operator manual Reciprocating compressor KCT blue T No 902350 00E...

Page 67: ...diagram 9 M Ersatz f r Ersatz durch a b c nderung Datum Datum Bearb Gepr Norm Name Ursprung 1 E 04 12 2018 Nr 46184 FKKDENTALT 00146 01 Plau Martin 3 13 1 2 38 1 2 38 37 37 1 36 7 9 2 9 3 9 1 9 5 9 4...

Page 68: ...densate outlet Compressed air cooler Solenoid valve Directional control valve Venting valve Directional control valve Silencer Compressed air dryer Nozzle 1 2 3 4 5 6 7 8 Blatt P I diagram legend Ersa...

Page 69: ...13 2 Dimensional drawing 13 Annex 13 2 Dimensional drawing No 902350 00E Operator manual Reciprocating compressor KCT blue T 59...

Page 70: ...r reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to o...

Page 71: ...eproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or m...

Page 72: ...reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or...

Page 73: ...reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or...

Page 74: ...production including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or ma...

Page 75: ...er reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to...

Page 76: ...er reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to...

Page 77: ...r reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to o...

Page 78: ...production including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or ma...

Page 79: ...reproduction including storage treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose Neither originals nor reproductions may be given to or...

Page 80: ...13 3 Electrical diagram 13 3 1 Electrical diagram 1 of 3 13 Annex 13 3 Electrical diagram 70 Operator manual Reciprocating compressor KCT blue T No 902350 00E...

Page 81: ...gives collective information on power supply voltages and frequencies for all machines The voltage and frequency and local conditions under which any particular machine may be used are given on the n...

Page 82: ...ation 1 Cover page DKK 03019 00 1 2 List of contents ZKK 03019 00 1 3 Block diagram UKK 03019 00 1 4 Circuit diagram SKK 03019 00 1 5 Equipment parts list GKK 03019 00 1 6 Component layout AKK 03019 0...

Page 83: ...oltage AC ungrounded Control voltage AC grounded earth conductor black 1 5mm H07V K red 1mm H05V K white 1mm H05V K green yellow 1 5mm H07V K 1 2 3 4 5 6 7 8 page Bl Block diagram electrical equipment...

Page 84: ...4 5 6 Pressure switch MDR3 3 pole P Compressor motor 1 PE 1 See service manual Technical specification Electrical connection 3G1 5mm 500V 70 C PE PE 25VA 110V 400V 0 25AT PUR UL CSA 3G1 5mm Timer modu...

Page 85: ...ei Nachbestellung von Ger ten und Maschinen sind alle in den stark umrandeten Spalten B und C angegebenen Daten aufzuf hren Die Daten in den Spalten D bis G sind zus tzlich unter Nennung dieser Ger te...

Page 86: ...2 3 4 5 6 7 8 page Bl Component layout Ersatz f r Ersatz durch a b c nderung Datum Datum Bearbeiter Gepr ft Norm Name Ursprung 1 1 29 01 2019 I Sitter Gegner 13 Annex 13 3 Electrical diagram 76 Opera...

Page 87: ...13 3 2 Electrical diagram 2 of 3 13 Annex 13 3 Electrical diagram No 902350 00E Operator manual Reciprocating compressor KCT blue T 77...

Page 88: ...gives collective information on power supply voltages and frequencies for all machines The voltage and frequency and local conditions under which any particular machine may be used are given on the n...

Page 89: ...e DKK 03004 02 1 2 List of contents ZKK 03004 02 1 3 Block diagram UKK 03004 02 1 4 Circuit diagram SKK 03004 02 1 5 Circuit diagram SKK 03004 02 2 6 Equipment parts list GKK 03004 02 1 7 Component la...

Page 90: ...inal strip control cabinet wiring for non designated conductors primary circuits Control voltage AC ungrounded Control voltage AC grounded earth conductor black 1 5mm H07V K red 1mm H05V K white 1mm H...

Page 91: ...W PE 2 2 kW 1 4G 2 5mm 500V 70 C PE PE I 5 5A 1 2 P Pressure switch 1 2 4 5 6 3A 4 3 6 5 I I I 13 14 21 22 7 2 4 6 1 3 5 U V W PE 3 4 2 2 kW 5 6 2 PE PE 4G 1 5mm 500V 70 C Volt free contact ALARM 1 2...

Page 92: ...PUR UL CSA 3G0 75mm Solenoid valve Ersatz f r Ersatz durch a b c nderung Datum Datum Bearbeiter Gepr ft Norm Name Ursprung 2 2 28 01 2019 Circuit diagram Function Group of functions D Sitter Gegner 10...

Page 93: ...ter Gepr ft Norm Name Ursprung 1 1 28 01 2019 Typ notwendige techn Daten z B Steuerspannung Frequenz Einstellbereich Type basic technical data e g control voltage frequency adjustable range sheet No s...

Page 94: ...l Component layout F1 F2 K70 Q1 0 PE X1 PE T11 Ersatz f r Ersatz durch a b c nderung Datum Datum Bearbeiter Gepr ft Norm Name Ursprung 1 1 28 01 2019 I Sitter Gegner 13 Annex 13 3 Electrical diagram 8...

Page 95: ...13 3 3 Electrical diagram 3 of 3 13 Annex 13 3 Electrical diagram No 902350 00E Operator manual Reciprocating compressor KCT blue T 85...

Page 96: ...cument gives collective information on power supply voltages and frequencies for all machines The voltage and frequency and local conditions under which any particular machine may be used are given on...

Page 97: ...s b c max 16A L1 N PE Pressure switch MDR2 P PE option Hour meter 1 2 3 4 5 6 Pressure switch MDR 3 3 pole P Compressor motor with Overload protection PE PUR UL CSA 3G1 5mm Timer module t PUR UL CSA...

Page 98: ...13 Annex 13 3 Electrical diagram 88 Operator manual Reciprocating compressor KCT blue T No 902350 00E...

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