KAESER AIRTOWER 3C Operator'S Manual Download

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Operator Manual

Screw Compressor

AIRTOWER 3C–7.5C

Tri-Voltage

9_6917 34 USE

manroland-document-no.:
80.95A EN F254

Manufacturer:

KAESER KOMPRESSOREN SE

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

Summary of Contents for AIRTOWER 3C

Page 1: ...Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE manroland document no 80 95A EN F254 Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130...

Page 2: ...Original instructions KKW SSXC 2 14 en Z1 SBA SCHRAUBEN TRI VOLTAGE AC SCB 20160524 092822...

Page 3: ...pply specifications 13 3 Safety and Responsibility 3 1 Basic instructions 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 re...

Page 4: ...ting the condensate drain 39 6 5 Refrigerated dryer Connecting the transformer according to the power supply 41 6 6 Making the Power Supply Connection 41 6 6 1 Changing main voltage connections 42 6 7...

Page 5: ...air receiver relief valve 75 10 14 3 Performing the test 75 10 14 4 Returning the machine to operational 76 10 15 Check the safety shut down due to excessive airend discharge temperature 76 10 16 Tes...

Page 6: ...Contents iv Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 7: ...18 Filter mat 60 Fig 19 Oil cooler 61 Fig 20 Air filter maintenance 62 Fig 21 Changing the belt 63 Fig 22 Checking the cooling oil level 64 Fig 23 Venting the machine 65 Fig 24 Replenishing the cooli...

Page 8: ...List of Illustrations vi Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 9: ...rant system 12 Tab 23 Power supply 115V 1 60Hz 13 Tab 24 Danger Areas 20 Tab 25 Safety Signs 21 Tab 26 Keys 29 Tab 27 Indicators 30 Tab 28 Display 31 Tab 29 Parameter 31 Tab 30 Condensate line 40 Tab...

Page 10: ...List of Tables viii Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 11: ...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 supp...

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: ...relating to one option only are marked with an option code e g H1 indicates that this section applies only to machines with machine mountings Option codes used in this oper ator manual are explained i...

Page 14: ...rial no psig cfm Characteristic Power supply of Compressor Value Voltage Phase Package FLA Hz Drive Motor FLA RPM HP Characteristic Power supply of Dryer Value Voltage Phase Package FLA Hz Refr compr...

Page 15: ...R 7 5C Minimum cut in tempera ture F 40 40 40 40 Typical airend discharge temperature during oper ation F 150 200 150 200 150 200 150 200 Maximum airend dis charge temperature au tomatic safety shut d...

Page 16: ...ntake air T Intake air temperature F H Maximum relative humidity of intake air 2 6 Ventilation The values given are minimum guide values AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7 5C Inlet apertur...

Page 17: ...ng pres sure psig AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7 5C 155 165 165 165 165 217 230 230 230 230 Tab 11 Safety relief valve activating pressure 2 9 Free air delivery FAD FAD cfm Maximum wor...

Page 18: ...erial Safety Data Sheets are available for each lubricant from your authorized KAESER Service representative Regardless of the lubricant selected the KAESER SIGMA lubricants will separate readily from...

Page 19: ...al food contact may occur 2 11 Cooling oil charge AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7 5C Total charge qt 3 0 3 0 3 0 3 0 Topping off volume qt minimum maximum 0 13 0 13 0 13 0 13 Tab 13 Coo...

Page 20: ...age on any unsymmetrical power supply Also do NOT operate package on power supplies like for example a three phase open delta or three phase star with non grounded neutral The machine requires a symme...

Page 21: ...recommend a ground conductor the same size as the power leads if local codes allow Rated power supply 208V 10 3 ph 60Hz AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 7 5C Pre fuse A 15 15 20 30 Supply...

Page 22: ...d global warming gas This refrigerant is required for the function The refrigerant system is hermetically sealed CT 4 CT 8 Refrigerant R 134a R 134a Global warming potential GWP 1430 1430 Charge quant...

Page 23: ...ations given in chapter 6 6 and the electrical diagram in chapter 13 3 if a common power supply is provided Rated power supply 115V 1 60Hz CT 4 CT 8 Pre fuse A 15 15 Supply 3xAWG14 3xAWG14 Consumption...

Page 24: ...ed ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated Do not use compressed air for any application that will bring it into direct contact with food...

Page 25: ...and take appropriate measures to safeguard persons and property have received adequate training and authorization for the safe installation and maintenance on this equipment Additional qualifications...

Page 26: ...rious 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 ensure...

Page 27: ...machine only with intact sound soundproofing Wear hearing protection if necessary The pressure relief valve blowing off can be particularly loud Operating fluids materials Operating fluids and materi...

Page 28: ...o dangers that can result in accidents with severe adverse health effects Wear protective clothing as necessary Suitable protective clothing examples Safety workwear Protective gloves Safety boots Eye...

Page 29: ...gen sulfide Do not position the machine in warm cooling outlet air from other machines Keep suitable fire extinguishing agents ready for use Commissioning operation and maintenance During commissionin...

Page 30: ...nd fire fighting measures 3 5 4 Danger Areas The table gives information on the areas dangerous to personnel Only authorized personnel may enter these areas Activity Danger area Authorized personnel T...

Page 31: ...rvice representative check the reliability of the safety func tions 3 8 Safety signs The diagram shows the positions of safety signs on the machine The table lists the various safety signs used and th...

Page 32: ...is free of voltage 23 Serious injury or death can result from loosening or opening component that is un der pressure and heavily spring loaded Do not open or dismantle the valve Call for authorized KA...

Page 33: ...ered 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 Sa...

Page 34: ...oncentrations risk of cardiac irregularity arrhythmia At very high concentration risk of asphyxia caused by oxygen deficiency Remove victim to the fresh air If necessary Respiration with respirator or...

Page 35: ...ay cause dangers for the environment Do not allow cooling oil to escape to the environment or into the sewage system Store and dispose of operating materials and replaced parts in accordance with loca...

Page 36: ...itable for the following uses Walking on standing or sitting on As resting place or storage of any kind of load Safe and reliable operation is only assured with the enclosure closed Removing the canop...

Page 37: ...ature Cooling oil recovered from the compressed air in the oil separator tank 7 and separator car tridge 10 gives up its heat in the oil cooler 9 The oil then flows through the oil filter 4 and back t...

Page 38: ...gerated dryer s condensate drain This condensate drain only functions when the dryer is switched on Parameter 8 ON Condensate may be drained manually if the dryer is switched off 4 5 Safety devices Th...

Page 39: ...If the floating relay contacts are connected to an external voltage source voltage may be present even when the machine is isolated from the power supply 4 7 Operating panel SIGMA CONTROL BASIC Keys F...

Page 40: ...inuously when acknowledged 15 Warning Lights yellow for maintenance work due Warning messages 16 Controller voltage Lights green when the power supply is switched on 19 ON Lights green when the machin...

Page 41: ...e work has been carried out The interval starts anew A password is required to change this parameter 3 Relief valve test mode This function switches the activating pressure check mode for the safety r...

Page 42: ...m possible setting Only an authorized KAESER service representative has the right to change this pa rameter F Main contactor Maximum permitted number of switching cycles reached This parameter value O...

Page 43: ...ontrol mode the controller toggles the machine between the operating modes LOAD and READY in order to compensate for air being drawn by consumers and to maintain the system pressure between the set mi...

Page 44: ...ine mountings These mountings allow the machine to be anchored firmly to the floor Fig 10 Machine mountings 4 Design and Function 4 11 Options 34 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri...

Page 45: ...fortably 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 hum...

Page 46: ...sunlight dust and rain 5 2 2 Ensuring the machine room ventilation Adequate ventilation of the machine room has several tasks It prevents subatmospheric pressure in the machine room It evacuates the...

Page 47: ...ent devices These conditions are detrimental to correct air treatment Air quality suffers To en sure the desired air quality when charging a vented air system we recommend the installation of an air m...

Page 48: ...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 Close shut off va...

Page 49: ...t all pressurized components and chambers completely 2 Connect a flexible pressure hose Further information The dimensional drawing in chapter 13 2 provides the size and position of the connection por...

Page 50: ...rial pressure resistant cor rosion proof Copper Stainless steel Plastics Hose line 1 For longer lengths please contact KAESER before installation Tab 31 Condensate collecting line Compressed air flow...

Page 51: ...supply voltages The pimary winding of the dryer transformer is not connected The refrigerated dryer will not run without connecting the control transformer according to the power supply Do only use t...

Page 52: ...ct taps on the control voltage transformer are connected according to the supply voltage If this is not correct change the connection to suit the power supply voltage 7 Danger of fatal injury from ele...

Page 53: ...necting the control transformer The pimary winding of the control transformer is not connected The machine will not run without connecting the control transformer according to the power supply Open th...

Page 54: ...ed 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 Close shut...

Page 55: ...machine To be checked See chapter Confirmed Are the operators completely familiar with safety regulations Have all the positioning conditions been fulfilled 5 Is a user s lockable power supply disconn...

Page 56: ...correctly set Contact an authorized KAESER service representative 7 5 Pouring cooling oil into the airend Before starting the compressor for the very first time and before re starting after a shutdow...

Page 57: ...ly disconnecting device and check that no voltage is present Changeover phase lines L1 and L2 Acknowledge any existing alarm messages and switch the machine on again 7 7 Setting the network setpoint p...

Page 58: ...yed in line 3 2 Press and hold enter for at least 3 seconds until the cursor flashes 3 Use the arrow keys to set the desired differential and confirm with Enter 7 Initial Start up 7 7 Setting the netw...

Page 59: ...ess the ON key The green ON LED lights continuously If a power failure occurs the machine is not prevented from automatic re starting It can start automatically again as soon as power is restored Resu...

Page 60: ...Setting parameters If a password is needed it is requested automatically Every action can be cancelled with the escape key If no key is pressed for ten seconds in the edit mode the display automatica...

Page 61: ...ey and confirm with enter The next character flashes 2 Repeat until all characters have been entered When the correct password is entered the parameters are displayed 3 Use the UP DOWN keys to change...

Page 62: ...uishes The machine is now ready to start again Warning message Message coming LED flashes Message gone LED extinguished Rectify fault or carry out maintenance The Warning LED extinguishes as soon as t...

Page 63: ...h but ton actuated Unlatch the EMERGENCY STOP push button 2 Drive motor alarm Overload protection compressor motor Check the overload relay setting Changing the oil separator cartridge Check minimum p...

Page 64: ...ning messages The fault code appears in the 4th line of the display field An adhesive label at the machine explains the fault code using symbols Fault code Symbol Meaning Remedy S Maintenance counter...

Page 65: ...e than twice per minute Receiver too small Increase size of receiver Airflow into the compressed air network restricted Increase air pipe diameters Check filter elements The differential between cut i...

Page 66: ...t 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 disconnecting device and verify the absence...

Page 67: ...enables the frequency of individual maintenance tasks and deviations from our recom mendations to be determined Further information A prepared list is provided in chapter 10 19 10 2 2 Resetting mainte...

Page 68: ...t every 2 years Condensate drain Change the service unit 10 5 Up to 6000 h Replace the drive belt 10 7 Annually Check that all electrical connections are tight Check safety relief valves 10 14 Check t...

Page 69: ...t service tasks Have service tasks carried out punctually taking ambient and operating conditions into ac count Interval Service task Up to 12000 h Service valves Up 12000 h every 4 years at the lates...

Page 70: ...Cooler maintenance Regular cleaning of the cooler ensures the reliable cooling of the machine and the compressed air Frequency of maintenance is mainly dependant on local operating conditions A leaki...

Page 71: ...ler repaired immediately by an authorized KAESER service repre sentative 10 5 Air Filter Maintenance Check that all sealing surfaces match each other The use of an unsuitable air filter element can pe...

Page 72: ...ed by an authorized KAESER service representative 10 7 Maintaining the drive belt Material Spare parts if required Precondition The power supply disconnecting device is switched off The device is lock...

Page 73: ...4 Loosen the pivot point fixing screw 2 only enough to allow the motor to shift to the side 5 Pivot the motor to the side and fix it in position with a screw 1 6 Place the new belt over the pulleys 7...

Page 74: ...evel with machine running under LOAD Result As soon as the minimum level is reached Replenish the cooling oil 10 9 Venting the machine depressurizing Venting takes place in three stages Isolate the co...

Page 75: ...the oil separator tank The oil circulation vents automatically as soon as the machine is stopped Check that the oil separator tank pressure gauge reads 0 psig The pressure gauge does not read 0 psig...

Page 76: ...both pressure gauges 2 and 9 show 0 psig after manual venting 10 10 Replenishing cooling oil The machine must be isolated from the compressed air network and completely vented be fore undertaking any...

Page 77: ...off valve closed insert the male hose fitting 6 into the hose coupling 3 Slowly open the shut off valve 7 to release pressure Disconnect the male hose fitting 6 and close the shut off valve 7 If manu...

Page 78: ...rt the machine and check the oil level again after about 10 minutes topping off if necessary 4 Switch off the machine and check for leaks 10 11 Changing the cooling oil Always change the oil filter an...

Page 79: ...r port with plug 5 Cooling oil level indicator 6 Male hose fitting 7 Shut off valve A Shut off valve open B Shut off valve closed 8 Maintenance hose 9 Hose coupling oil drain 10 Shut off valve control...

Page 80: ...hose cou pling 3 3 Connect the maintenance hose to the exter nal air supply 4 Open the shut off valve 7 until the pressure gauge 2 on the oil separator tank reads 43 73 psig 5 Close the shut off valv...

Page 81: ...in after about 10 minutes topping off if necessary 5 Switch off the machine and visually check for leaks 10 12 Changing the oil filter The machine must be isolated from the compressed air network and...

Page 82: ...ion network 3 Switch on the power supply and reset the maintenance interval counter 4 After approx 10 minutes of operation Check the cooling oil level and top off if necessary 5 Switch off the machine...

Page 83: ...Oil separator cartridge Changing the oil separator cartridge 1 Unscrew the oil separator cartridge counterclockwise and wipe off any drops of oil 2 Lightly oil the new filter s gasket 3 Turn the oil f...

Page 84: ...any work on the pressure system Never operate the machine without correctly functioning safety relief valves Material Service fittings with accessories fixed to the machine Precondition The machine i...

Page 85: ...ady for operation again as described in section 10 14 4 10 14 3 Performing the test The machine starts and runs under LOAD as long as the ON button is held down Pressure in the receiver to be checked...

Page 86: ...shut off valve between the machine and the air distribution network 10 15 Check the safety shut down due to excessive airend discharge temperature The machine should shut down if the airend discharge...

Page 87: ...arp objects to clean the refrigerant condenser The refrigerant condenser could be damaged Avoid creating clouds of dust Precondition The power supply disconnecting device is switched off The device is...

Page 88: ...drain 3 With your other hand push and hold the TEST key at the condensate drain for at least 2 seconds Result As soon as the condensate drain opens you will feel a short burst at the condensate drain...

Page 89: ...he condensate line 4 Press the snap fastener 5 and carefully remove the control module 2 from the service unit 1 5 Carefully loosen the union nut 13 at the shut off valve 9 until remaining residual ai...

Page 90: ...hat would impair its function The condensate drain only functions when the dryer is in operation Condensate can be drained manually from the air receiver when the dryer is not operat ing Material If r...

Page 91: ...ndition The air receiver is pressurized Wear eye and ear protection 1 With the shut off valve closed insert the hose male fitting 6 into the hose coupling 9 2 Open the shut off valve 11 3 Slowly open...

Page 92: ...nd service work carried out in the checklist below Date Maintenance task carried out Operating hours Signature Tab 45 Logged maintenance tasks 10 Maintenance 10 19 Documenting maintenance and service...

Page 93: ...e to the machine resulting from the use of unsuita ble spares or operating fluids materials Use only original KAESER parts and operating fluids materials Have an authorized KAESER service representati...

Page 94: ...s are given at the end of this manual 11 5 Replacement parts for service and repair Use these parts lists to plan your material requirement according to operating conditions and to or der the required...

Page 95: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 85...

Page 96: ...11 Spares Operating Materials Service 11 5 Replacement parts for service and repair 86 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 97: ...pletely cool down 2 Disconnect all air and electrical connections 12 2 Packing A wooden crate is required for overland transport to protect the machine from mechanical damage Other measures must be ta...

Page 98: ...dition Transport only by forklift truck or lifting gear only by personnel trained in the safe transportation of loads Make sure the danger area is clear of personnel 12 4 2 Transport with a forklift t...

Page 99: ...ting gear Do not attach the lifting gear to any of the machine components 2 Use the lifting gear correctly and lift the machine carefully 12 5 Disposal When disposing of a machine drain out all liquid...

Page 100: ...rcuit still contains both refrigerant and oil Refrigerant and oil must be drained and disposed of by authorized personnel 12 Decommissioning Storage and Transport 12 5 Disposal 90 Operator Manual Scre...

Page 101: ...Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage...

Page 102: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 92 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 103: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 93...

Page 104: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 94 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 105: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 95...

Page 106: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 96 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 107: ...13 2 Dimensional Drawing 13 Annex 13 2 Dimensional Drawing 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 97...

Page 108: ...ung darf nur ber CAD ge ndert werden 02 02 2012 Projektion A3 10219789 USE 00 nderungs Nr Ma stab Original Dokument TZM Dokument TZD Bezeichnung Sprache Blatt Datum Name Gez Bearb Freigeg 1 von 1 04 0...

Page 109: ...13 3 Electrical Diagram 13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 99...

Page 110: ...13 Annex 13 3 Electrical Diagram 100 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 111: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 101...

Page 112: ...13 Annex 13 3 Electrical Diagram 102 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 113: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 103...

Page 114: ...13 Annex 13 3 Electrical Diagram 104 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 115: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 105...

Page 116: ...13 Annex 13 3 Electrical Diagram 106 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 117: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 107...

Page 118: ...13 Annex 13 3 Electrical Diagram 108 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 119: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 109...

Page 120: ...13 Annex 13 3 Electrical Diagram 110 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 121: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 111...

Page 122: ...13 Annex 13 3 Electrical Diagram 112 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

Page 123: ...13 Annex 13 3 Electrical Diagram 9_6917 34 USE Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 113...

Page 124: ...13 Annex 13 3 Electrical Diagram 114 Operator Manual Screw Compressor AIRTOWER 3C 7 5C Tri Voltage 9_6917 34 USE...

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