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7 Initial Start-up

7.1 Ensuring safety

Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.

Disregard of warning instructions can cause serious injuries!

Please take note of all safety instructions

Disregard of safety notes can cause unforeseeable dangers!
➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.

When working on live components

Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that 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. The following safety concerns relate to any work on components that could be under

pressure.
➤ Isolate the machine from the air main by closing the user's shut-off valves.
➤ De-pressurise all pressurised components and enclosures.
➤ The machine pressure gauge must read zero.
➤ Do not open or dismantle any valves.

When working on the drive system

Touching voltage carrying components can result in electric shocks, burns or death.

Touching the fan while the machine is running can result in serious injury.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Do not open the cabinet while the machine is switched on.

Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

7

Initial Start-up

7.1

Ensuring safety

26

Service Manual Reciprocating compressor
Premium compact W

No.: 9_9418 20E

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Summary of Contents for Premium Compact W 200/4

Page 1: ...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 ...

Page 2: ...Original instructions KKW PPWCO 2 00 en SBA PREMIUM COMPACT TRAGBAR 20120822 115136 ...

Page 3: ...se 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 ...

Page 4: ...enance 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...

Page 5: ...age 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 ...

Page 6: ...Contents iv Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

Page 7: ... 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 Illustra...

Page 8: ...List of Illustrations vi Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

Page 9: ...15V 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...

Page 10: ...List of Tables viii Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

Page 11: ...the nameplate when ordering documents 1 3 Copyright This service manual is copyright protected Queries regarding use or duplication of the documenta tion should be referred to KAESER Correct use of information will be fully supported 1 4 Symbols and labels Please note the symbols and labels used in this document 1 4 1 Warnings Warning notices indicate dangers that may result in injury when disrega...

Page 12: ...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 Warning notices for damages are identified by their signal term Signal term Meaning Consequences of non compliance NOTE Warns of a potentially dangerous situation Damage to property is possible Tab 2 Danger l...

Page 13: ...ption only are marked with an option code e g H1 indicates that this section applies only to machines with screw in machine feet Option codes used in this service manual are explained in chapter CROSS_REFERENCE_FAILED Information referring to potential problems are identified by a question mark The cause is identified in the help text as is a solution This symbol identifies important information o...

Page 14: ...nt temperature Tab 3 Nameplate 2 2 Weight The weight given is the maximum The actual weight depends on equipment fitted Premium compact Weight kg 160 4 31 200 4 32 250 4 33 300 4 34 Tab 4 Weight 2 3 Compressor block Premium compact Compressor block type Theoretical dis place ment l min FAD at 6 bar l min Number of cylin ders 160 4 KCC 160 160 98 1 200 4 KCC 200 200 115 1 250 4 KCC 250 250 150 1 30...

Page 15: ...ct Cut in pressure bar Cut out pressure bar Pressure differ ential Δp bar Setting range bar 160 4 16 20 4 2 5 200 4 7 9 2 3 4 250 4 7 9 2 3 4 300 4 7 9 2 2 4 Minimum adjustment range Cut in pressure cut out pressure Tab 7 Pressure switch setting 2 6 Pressure Premium compact Maximum working pressure bar Pressure relief valve activating pressure bar 160 4 20 20 200 4 10 11 250 4 10 11 300 4 10 11 Ta...

Page 16: ...enter in the table Premium compact Compressor block type Rated power kW Synchronous speed rpm 50 Hz Protection rating 160 4 KCC 160 1 1 3000 200 4 KCC 200 1 1 3000 250 4 KCC 250 1 25 3000 300 4 KCC 300 1 5 3000 Tab 10 Power and speeds Permissible starting frequency Take the permissible starting frequency of the motor from the table below Rated power kW Permissible starting frequency 1 h 1 1 20 1 2...

Page 17: ... 250 0 13 0 05 KCC 300 0 13 0 05 Tab 13 Compressor oil charge 2 10 Power Supply Basic requirements The machine is designed for a power supply conforming to EN 60204 1 IEC 60204 1 sec tion 4 3 In the absence of other user specified conditions the limits laid down in this standard must be ad hered to It is recommended that the user and the supplier reach an agreement on the basis of the EN 60204 1 A...

Page 18: ... 1 5 13 0 200 4 16 3 x 1 5 13 0 250 4 20 3 x 2 5 15 5 Tab 14 Mains supply 110V 1 50Hz Rated power supply 230V 5 1 50Hz If the machine is delivered with a Schuko plug to CEE 7 4 or CEE 7 7 the power socket may be fused at 16 A slow blow Premium compact Mains fusing A Supply cable mm2 Current consumption A 160 4 10 3 x 1 5 6 2 200 4 10 3 x 1 5 6 2 250 4 10 3 x 1 5 7 4 300 4 16 3 x 1 5 10 Tab 15 Main...

Page 19: ... 5 1 60Hz Premium compact Mains fusing A Supply cable mm2 Current consumption A 160 4 10 3 x 1 5 6 5 200 4 10 3 x 1 5 6 5 250 4 300 4 Tab 19 Mains supply 220V 1 60Hz Rated power supply 230V 5 1 60Hz Premium compact Mains fusing A Supply cable mm2 Current consumption A 160 4 200 4 250 4 16 3 x 1 5 7 8 300 4 20 3 x 2 5 11 2 Tab 20 Mains supply 230V 1 60Hz 2 11 Mains conditions The machines listed in...

Page 20: ...arts please consult the manufacturer Specification related to the sum of impedances in external and neutral lines Tab 21 Network impedance 2 12 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 standstill time x 100 Example 12 minutes 20 minutes x 100 60 The following values are va...

Page 21: ... 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 Do not touch hot components during operation or after shutdown Wait until they have cooled before touching These compo...

Page 22: ...tions are of legal age have read are conversant with and adhere to the safety instructions and sections of the ser vice manual applicable to installation and maintenance are fully conversant with the safety concepts and regulations of electrical and compressed air engineering are able to recognise the possible dangers of electrical and compressed air devices and take appropriate measures to safegu...

Page 23: ...petent person e g KAESER Service Techni cian Every 5 years after installation 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 Competent person e g KAESER Service Techni cian Every 10 years after installation or the last inspection if PS x V 1000 Approved supervisory body The inspection interval is...

Page 24: ...otherwise isolate the machine from the distribution network to ensure that no compressed air can flow back into the machine De pressurise all pressurised components and enclosures Do not carry out welding heat treatment or mechanical modifications to pressurised compo nents e g pipes and vessels as this affects the component s resistance to pressure The safety of the machine is no longer ensured C...

Page 25: ...ating fluids Keep suitable fire extinguishing agents ready for use Use only KAESER approved operating materials Unsuitable spare parts Use only spare parts approved by the manufacturer for use in this machine Unsuitable spare parts compromise the safety of the machine Use only genuine KAESER replacement parts on pressure bearing parts Conversion or modification of the machine Do not permit convers...

Page 26: ...st be protected from frost direct sunlight dust rain and splashing water Do not operate in areas in which specific requirements regarding 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 wi...

Page 27: ...ies Give clear instructions on reporting faults and damage to the machine Give instructions on fire reporting and fire fighting measures 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 and notices are cle...

Page 28: ...gloves 3 Risk of injury caused by an automatic machine start Switch off and lock out the mains isolating devices and check that no voltage is present before opening any machine enclosure or guard 4 35 kg Weight Danger of injury from lifting or carrying the machine At least two persons should be used to carry the machine Tab 24 Safety signs 3 8 Information signs The table lists the various informat...

Page 29: ...ing water if present Warn and move endangered personnel to safety Help incapacitated persons Close the doors When trained accordingly Attempt to extinguish the fire Extinguishing substances Suitable extinguishing media Foam Carbon dioxide Sand or soil Unsuitable extinguishing media Strong jet of water 3 9 2 Treating injuries from handling cooling oil Eye contact Compressor oil can cause irritation...

Page 30: ...etermine its suitability for his specific application Furthermore we accept no warranty obligation for the use of unsuitable parts or operating materials un authorised modifications incorrect maintenance incorrect repair Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials Obtain confirmation from KAESER that your specific operating conditions are s...

Page 31: ...l 17 Plastic canopy 18 Handle with hose hook 19 Power cable hook Machine Atmospheric air is drawn through a filter into the compression chamber of the block The air is drawn in during the downward stroke of the piston It is compressed during the upward stroke The compressed air flows through the air pipe giving up most of its heat then via the check valve into the air receiver The check valve prev...

Page 32: ...e between the op erating modes LOAD and STANDSTILL 4 3 Safety devices The following safety devices are provided and may not be modified in any way Pressure relief valve The pressure relief valve protects the machine from excessive pressure It is factory set Check valve The check valve prevents the flow of compressed air from the air receiver back to the compressor block when the machine is stopped...

Page 33: ... for use in Potentially Explosive Atmospheres Ensure sufficient and suitable lighting such that the display can be read and work carried out comfortably and safely Keep suitable fire extinguishing agents ready for use Ensure that required ambient conditions are maintained Required ambient conditions may be Maintain ambient temperature and humidity Ensure the appropriate composition of the air with...

Page 34: ...mpressed air system Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure Isolate the machine from the air main by closing the user s shut off valves De pressurise all pressurised components and enclosures The machine pressure gauge must read zero Do not op...

Page 35: ...n relevant regulations IEC 364 for example or DIN VDE 0100 and in national accident prevention regulations BGV A3 in Germany Also ob serve the regulations of the local power utility company 2 Test the overcurrent protection cut out to ensure that the time it takes to disconnect in re sponse to a fault is within the permitted limit 3 Select supply cable conductor cross sections and fusing in accord...

Page 36: ...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 following safety concerns relate to any work on components that could be under pressure Isolate the machine from the air main by closing the user s shut off valves De pressurise all pressurised components and enclosures Th...

Page 37: ...with safety regulations Have all the positioning conditions been fulfilled 5 Does the power supply conform to the specifications on the name plate 2 1 Are the power supply cable conductor cross sections and fuse ratings adequate 2 10 Have all electrical connections been checked for tightness Has the check been repeated after 50 operating hours Is the connection to the air network made with a flexi...

Page 38: ...l the air receiver when new can be useful in checking the machine s performance at a later date Precondition Machine at operating temperature 1 Disconnect all air consumers 2 Switch on the power supply isolating device 3 Measure the air receiver charging time 4 Enter the charging time and machine model in the table Machine model Receiver charging time from 3 8 bar min s Tab 28 Air receiver chargin...

Page 39: ... air Compressed air and devices under pressure can injure or cause death if the contained en ergy is released suddenly Do not loosen or open any component that is still under pressure 5 Adjust the pressure switch setting according to the table Adjusting the setting Function Cut out pressure is to be increased Turn the adjusting screw 3 clockwise in the direction Cut out pressure is to be decreased...

Page 40: ... fluctuation to the required pressure and holds it constant A pressure adjustment is possible to suit individual operating conditions Pressure setting can only be adjusted when a pressure switch is fitted and under pressure Maximum range of adjustment 0 5 bar 20 bar Precondition The machine is isolated from the air consumers Fig 6 Setting the pressure regulator 1 Adjusting knob 2 Locking collar 3 ...

Page 41: ...ig 7 Switching on and off 1 ON OFF switch Switching on 1 WARNING Compressed air Serious injury is possible Never direct compressed air at persons or animals Make sure that no one is working on the machine 2 Switch on the power supply isolating device 3 Switch on the compressor at the pressure switch The compressor motor starts so long as the network pressure is lower than the setpoint cut out pres...

Page 42: ... opening Maintain or replace the unload ing valve Bearing damage Contact KAESER Service Piston seized due to insufficient or incorrect oil Contact KAESER Service Fault in the power supply Check power supply Oil level too high Drain out some oil Machine runs hot Ambient temperature too high Reduce the ambient tempera ture Fan cannot draw air freely Ensure unrestricted flow of air to the fan Valves ...

Page 43: ... pressure switch while the machine is run ning Defective switch diaphragm Replace the pressure switch The venting valve is not clos ing Maintain or replace the unload ing valve Whistling sound from the cylin der head Cylinder head fixing screws loose Gasket defective Tighten the cylinder head fixing screws Replace gasket The pressure relief valve blows off before the cut out pressure is reached Pr...

Page 44: ...e Check that 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 The following safety concerns relate to any work on components that could be under pressure Isolate the machine from the air main by closing the user s shut off valves De pressurise all pressur...

Page 45: ...ceiver 10 10 Annually Carry out air filter maintenance 10 4 Maintain the check valve 10 12 Check that all electrical connections are tight Check the pressure relief valve 10 9 Variable see table 32 Change the cooling oil 10 8 h operating hours Tab 31 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 c...

Page 46: ...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 As required Respiratory protection 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 8 Cle...

Page 47: ...ce 1 Air filter 2 Inlet air opening 3 Air filter insert 4 Air filter housing 1 Take of the filter housing 2 Withdraw the filter insert 3 Clean the filter insert with a solvent based cleaner 4 Clean the housing and sealing faces 5 Insert the dried filter insert in the rubber cap and replace the cap on the filter housing 6 Mount the air filter on the cylinder head such that the inlet opening is faci...

Page 48: ...p the compressor oil Material Compressor oil Precondition The supply disconnecting device is switched off The disconnecting device is locked off A check has been made that no voltage is present The machine has cooled down CAUTION The machine can be damaged by unsuitable oil Never mix different types of oil Never top up with a different type of oil to that already used in the machine The type of co...

Page 49: ...n the oil completely from the compressor block Change the oil immediately if it becomes milky This indicates a high condensate content Contact KAESER Service if condensate is detected in the oil Material Compressor oil Oil receptacle Precondition Machine at operating temperature The supply disconnecting device is switched off the device is locked off a check has been made that no voltage is presen...

Page 50: ...t 3 Start the 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 9 Pressure relief valve checking To test the pressure relief valve it must be removed from the machine by a KAESER Service Technician and installed on a test rig Further information Details about the activating pressure of the pressure re...

Page 51: ...user s shut off valve between the machine and the air distribution network 3 Turn the knurled knob on the pressure relief valve anticlockwise until air blows off 4 Then turn the knurled knob back to its original position 5 Open the user s shut off valve between the machine and the air distribution network Result The machine can now be started Pressure relief valve does not blow off Have the defect...

Page 52: ...ssure system Precondition The supply disconnecting device is switched off The disconnecting device is locked off A check has been made that no voltage is present The machine has cooled down Fig 15 Venting the machine 1 Condensate drain tap 1 DANGER Compressed air Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly Isolate the compressor ...

Page 53: ...at no voltage is present The machine is fully vented no pressure Verify the absence of pressure using a suitable measur ing device pressure gauge The machine has cooled down The user s shut off valve between the machine and the air network is closed Fig 16 Cleaning the check valve 1 Enclosure 2 Screw plug 3 Valve cone 4 Valve seat 5 Spring 6 O ring 1 CAUTION Danger of burns from hot components Wea...

Page 54: ... the pressure switch unloading valve 1a The unloading valve can be cleaned 1b The unloading valve must be replaced 2 Screw 3 Screw plug 4 Ball 5 Spring 6 Gasket 7 Pin 8 Screw fitting Unloading valve 1a can be cleaned Unloading valve 1b must be replaced Open the valve carefully 1 Remove the fitting from the valve 2 Loosen the securing screws and take off the unloading valve 3 Remove the screw plug ...

Page 55: ...rating temperature Start the machine and measure the receiver charging time Result If there is a significant difference in the charging time to when the machine was new have KAESER Service check or replace the valves Further information See chapter 7 5 for air receiver charging time measurement 10 Maintenance 10 14 Cylinder head and valves No 9_9418 20E Service Manual Reciprocating compressor Prem...

Page 56: ...nance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 34 Logged maintenance tasks 10 Maintenance 10 15 Documenting maintenance and service work 46 Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

Page 57: ... quality consumable parts and operating fluids materials may damage the machine 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 18 Consumable parts 10 Air filter element 20 Check valve Machine Name Quantity Number Air filter eleme...

Page 58: ...reement 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 Spares for service and repair Make sure that any service or repair tasks not described in this manual are carried out by an authorised KAESER Service Technician 11 Spares Operating Materials Service 11 4 Service Addresses 48 Ser...

Page 59: ...y cool down 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 Drain all condensate 4 Disconnect all air and electrical connections 5 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 Other...

Page 60: ...om heavy weight Only lift or carry the machine briefly and only if body condition allows Observe local accident prevention regulations 2 If necessary use two people to carry the machine A handle and wheels are provided to assist in transporting 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 ...

Page 61: ...13 Annex 13 1 Dimensional Drawing 13 Annex 13 1 Dimensional Drawing No 9_9418 20E Service Manual Reciprocating compressor Premium compact W 51 ...

Page 62: ...13 Annex 13 1 Dimensional Drawing 52 Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

Page 63: ...13 2 Electrical Diagram 13 Annex 13 2 Electrical Diagram No 9_9418 20E Service Manual Reciprocating compressor Premium compact W 53 ...

Page 64: ...13 Annex 13 2 Electrical Diagram 54 Service Manual Reciprocating compressor Premium compact W No 9_9418 20E ...

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