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4 Design and Function

4.1 Outline of the machine

4.1.1 Machine structure

Fig. 2 Machine overview

Air filter

Compressor block

Compressor motor

Oil filler port

Oil sight glass

Oil drain plug

Arrow showing direction of rotation

Compressed air outlet

Air pipe*

Air cooler*

Fan with cowl*

Cylinder or collecting pipe

relief valve*

Air cooler

relief valve*

Solenoid valve*

Sound enclosure*

machine-dependent

4.1.2 Machine function

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 passes through the inter-stage cooling pipe into the second cylinder where it is fur‐

ther compressed.

Design and Function

4.1

Outline of the machine

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

No.: 9_5753 24 E

Содержание EPC 150-2-G

Страница 1: ...mbly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser...

Страница 2: ...KKW PEPC 2 04 en SBA KOLBEN AGGREGAT 2 STUFIG 20170303 120300...

Страница 3: ...3 Safety and Responsibility 3 1 Basic instructions 15 3 2 Specified use 15 3 3 Improper use 15 3 4 User s responsibilities 16 3 4 1 Observe statutory and universally accepted regulations 16 3 4 2 Dete...

Страница 4: ...tallation examples 38 6 7 1 Safety and Control Devices 38 6 7 2 Two machines with one air receiver 40 6 8 Connecting the machine to the power supply 40 6 9 Options 41 6 9 1 Oil level monitoring 41 6 9...

Страница 5: ...e machine de pressurising 72 10 13 Solenoid valve maintenance 73 10 13 1 Cleaning the solenoid valve 74 10 13 2 Replacing the solenoid valve 75 10 14 Cylinder head and valves 75 10 14 1 Checking cylin...

Страница 6: ...Contents iv Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

Страница 7: ...EPC 230 2 G 46 Fig 21 Installing the sound enclosure EPC 150 2 G EPC 230 2 G 47 Fig 22 Modifying the air filter EPC 420 2 G EPC 550 2 G 48 Fig 23 Installing the sound enclosure EPC 420 2 G EPC 550 2 G...

Страница 8: ...List of Illustrations vi Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

Страница 9: ...b 20 Supply details 230V 3 60Hz 11 Tab 21 Supply details 380V 3 60Hz 11 Tab 22 Supply details 440V 3 60Hz 12 Tab 23 Supply details 460V 3 60Hz 12 Tab 24 Option C5 Connection data for oil level monitor...

Страница 10: ...List of Tables viii Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

Страница 11: ...ained in them Make sure you provide 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 th...

Страница 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...

Страница 13: ...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 referri...

Страница 14: ...Options The table contains a list of possible options Enter options here as a reference Option Option code Provided Oil level monitoring C5 Silenced air filter H9 Air filter with plastic casing H10 Ca...

Страница 15: ...with ISO 1217 2009 Annex C 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...

Страница 16: ...alve pressure data Air cooler relief valve 1 Maximum working overpres sure bar 15 Pressure relief valve activating pressure bar 17 5 1 EPC 420 2 G to EPC 1000 2 G Tab 10 Pressure indication for pressu...

Страница 17: ...1500 1800 EPC 420 2 G 3 0 1500 1800 EPC 550 2 G 4 0 1500 1800 EPC 750 2 G 5 5 1500 1800 EPC 1000 2 G 7 5 1500 1800 Tab 12 Motor power and speed Permissible starting frequency The permissible starting...

Страница 18: ...requirements The machine is designed in accordance with the conditions for an electrical power supply specified in EN 60204 1 IEC 60204 1 section 4 3 If no other conditions are specified by the operat...

Страница 19: ...cables Table 21 Single layer on wall or floor Spacing outside diameter For other application conditions check and determine the supply diameters according to DIN VDE 0100 and DIN VDE 0298 4 2013 06 or...

Страница 20: ...p fuse A Supply ca ble 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...

Страница 21: ...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 START CONTROL Tab 20 Supply details 230V 3 60Hz Rated voltage 380V 10 3 60Hz EPC Current drawn A Di...

Страница 22: ...p fuse A Supply ca ble 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...

Страница 23: ...onditions at 400V 3 50Hz Compressor model Start configuration Maximal permissible motor starts 1 1 h Highest permissible System impedance2 Zmax EPC 150 2 G Direct online 20 0 767 EPC 230 2 G 20 0 360...

Страница 24: ...l Permissible duty cycle Cycle time min EPC 150 2 G 70 2 20 EPC 230 2 G 70 2 30 EPC 420 2 G 70 3 30 EPC 550 2 G 70 3 30 EPC 750 2 G 70 4 30 EPC 1000 2 G 70 4 30 Tab 26 Machine duty cycle 2 Technical S...

Страница 25: ...ly 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 applic...

Страница 26: ...perating manual relevant to operation they have received adequate training and authorization to operate electrical and compressed air devices Authorised installation and maintenance personnel have the...

Страница 27: ...ng the machine the user must make sure there is ad equate protection against electric shock from direct or indirect contact Before starting any work on electrical equipment Switch off and lock out the...

Страница 28: ...ds are in place and secured before re starting Temperature High temperatures are generated during compression Touching hot components may cause inju ries Avoid contact with hot components These includ...

Страница 29: ...dangers may arise if you modify or extend the compressed air station When extending or modifying the compressed air system Check the blow off capacity of pressure relief valves on air receivers and c...

Страница 30: ...rs the machine must be protected from frost direct sunlight dust rain and splashing water Do not operate in areas in which specific requirements with regard to explosion protection are in force For in...

Страница 31: ...pen or destroy any components taken from the machine De commissioning storage and disposal Improper handling of old operating fluids and components represent a danger for the environment Drain off flu...

Страница 32: ...t labels and notices are clearly legible Further information More information on safety devices is contained in chapter 4 section 4 4 3 8 Safety Signs The diagram shows the positions of safety signs o...

Страница 33: ...ine Maintain the air filter regularly Check the oil level regularly and change the oil at the correct intervals Tab 29 Information signs 3 10 In emergency 3 10 1 Correct fire fighting Suitable measure...

Страница 34: ...continues Ingestion Wash out the mouth immediately Do not induce vomiting Seek medical aid 3 11 Warranty This operating manual does not contain any independent warranty commitment Our general terms an...

Страница 35: ...for the environment Do not allow compressor oil to escape to the environment or into the waste water system Store and dispose of operating materials and replaced parts in accordance with local environ...

Страница 36: ...ve 13 Air cooler relief valve 14 Solenoid valve 15 Sound enclosure machine dependent 4 1 2 Machine function Atmospheric air is drawn through a filter into the compression chamber of the block The air...

Страница 37: ...lls below minimum Fig 3 Option C5 Oil level monitoring 1 Oil level monitoring 4 2 2 Option H9 Silenced air filter The air filter reduces the noise level of the machine It also cleans the inlet air Fig...

Страница 38: ...4 2 5 Option H20 Screwable rubber pads for air receiver mounting Screwable rubber pads different models are intended for vibration free and low noise mounting of the machine e g on an air receiver Fig...

Страница 39: ...d 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 WARNING Controller voltage Inc...

Страница 40: ...the maximum working pressure and the cross section of the connection between the compressor and the air network Pressure switch The pressure switch regulates the working pressure of the air network Th...

Страница 41: ...retrospectively fitted with a sound enclosure Further information Instructions on installation of a sound enclosure can be found in chapter 6 10 4 Design and Function 4 5 Accessories No 9_5753 24 E As...

Страница 42: ...e 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 Re...

Страница 43: ...may hot cooling air from other 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 ventilatio...

Страница 44: ...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 exceed the permis...

Страница 45: ...o 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 sa...

Страница 46: ...10 Fitting the rubber pads 1 Rubber pad 2 Hexagonal nut Remove the wooden frame from the base plate Fit the rubber pads to the base plate with hexagon nuts 6 4 Replacing the air filter Mount the air...

Страница 47: ...injury or death can result from loosening or opening components under pressure Vent all pressurized components and enclosures 2 A shut off valve and check valve must be installed by the user in the co...

Страница 48: ...loosening or opening components under pressure De pressurise all pressurised components and enclosures Verify pressure free status 3 Install the venting valve either on the pressure switch or at the...

Страница 49: ...e gauge 8 Shut off valve compressed air outlet 9 Shut off valve compressed air inlet 10 Shut off valve condensate drain 11 Nozzle machine dependent Install safety and regulating devices at the user si...

Страница 50: ...d line 12 Swan neck Higher positioned feed lines should generally be implemented as a swan neck and with a gra dient of at least 2 6 8 Connecting the machine to the power supply Precondition The power...

Страница 51: ...connection 6 DANGER Danger of fatal injury from electric shock Switch off and lock out the power supply disconnecting device and verify the absence of voltage 7 Connect the machine to the power supply...

Страница 52: ...f the compressor at the pressure switch Connecting oil level monitoring for star delta starting Machines with star delta starting require additional control and connection parts and an external contro...

Страница 53: ...setting 1 Switch cover 2 Screw 3 Red arrow 4 Sensing contact 5 Adjustment range 6 Higher oil level 7 Lower oil level 1 Switch off the machine 2 DANGER Electric voltage Risk of fatal injury caused by...

Страница 54: ...2 Threaded connection 1 Remove the wooden frame from the base plate 2 Use appropriate fixing elements to anchor the rubber pads 3 CAUTION There is a danger of tilting because of the high centre of gra...

Страница 55: ...tric voltage Risk of fatal injury caused by contact with live components Switch off and lock out the power supply disconnecting device and check that no voltage is present 2 Remove the cable from the...

Страница 56: ...the screws 2 Unscrew the air filter from the cylinder head and clean if necessary 3 Screw the elbow into the cylinder head and then the air filter to the elbow Further information See chapter 10 4 for...

Страница 57: ...ith serrated locknuts 3 Position the base plate and secure with hex head screws to the rubber pads 2 4 Insert the rubber pads 5 through the base plate and secure to the Z profiles 5 Place the compress...

Страница 58: ...er from the cylinder head and clean if necessary 2 Screw the supplied elbow into the cylinder head and then the air filter to the elbow Further information See chapter 10 4 for information on air filt...

Страница 59: ...uts 2 Insert rubber pads 2 and 3 through the Z profiles and secure with serrated locknuts 3 Position the base plate and secure with hex head screws to the rubber pads 2 4 Place the spacers 6 in the ho...

Страница 60: ...2 G 1b EPC 1000 2 G 2 Angle 2a EPC 750 2 G 2b EPC 1000 2 G A Before modification B After modification 1 Unscrew the air filter from the cylinder head and clean if necessary 2 Screw the supplied elbow...

Страница 61: ...nsert the rubber pads 2 and machine mounts through the Z profile and secure with serrated locknuts 3 Position the base plate and secure with hex head screws to the rubber pads 2 4 Place the spacers 6...

Страница 62: ...air inlet louvre to the enclosure hang the panel exhaust louvre in the enclo sure and secure it with the snap fasteners 6 Installation 6 10 Retrofitting the sound enclosure accessory 52 Assembly and o...

Страница 63: ...e 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 an...

Страница 64: ...ed 5 Is a user supplied lockable power supply disconnection device in stalled 6 8 Are the tolerance limits of the mains voltage power supply within the permissible tolerance limits of the nominal volt...

Страница 65: ...triggered by voltage fluctuations temperature influences or component toleran ces 1 Read the rated motor current from the nameplate and calculate the correct protection setting 2 Check the motor prot...

Страница 66: ...the shut off valve to the air network 2 Switch on the power supply disconnecting device The machine switches to LOAD and delivers compressed air Watch for any faults occurring in the first hour of ope...

Страница 67: ...Automatic restart Serious injury is possible The machine restarts automatically when power is restored follow ing a power cut Make sure that no one is working on the machine 2 Switch the machine on a...

Страница 68: ...ontroller Result The machine starts as soon as network pressure is lower than the cut out pressure Switching off 1 Switch off the machine via the external controller 2 Switch off and lock out the powe...

Страница 69: ...off the machine via the external controller 2 Switch off and lock out the power supply isolating device 8 Operation 8 1 Switching on and off No 9_5753 24 E Assembly and operating manual 2 stage piston...

Страница 70: ...short circuit Call KAESER SERVICE Compressor block defective Call KAESER SERVICE Undervoltage trip in the user s pressure switch of the oil level indication option C5 activated Check undervoltage trip...

Страница 71: ...AESER SERVICE technician Broken pressure valve reed Have valve plate replaced Machine leaks air Seal the leaks or replace the components Leakage from an air consumer connected to the air system Check...

Страница 72: ...ng defective Call KAESER SERVICE Dirt or foreign bodies on the valve seat Let the pressure relief valve blow off briefly Pressure relief valve on the air cooler blows off prematurely Cooler clogged Co...

Страница 73: ...ere 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 foll...

Страница 74: ...punctually taking ambient and operating conditions into consider ation Interval Maintenance task See chapter Daily or every 24 operat ing hours Check the oil level 1 10 8 Every 500 h Carry out air fil...

Страница 75: ...ting conditions into ac count Interval Service task At the latest every 2 years Replace the air filter element Up to 3000 h Have cylinder head and valves checked Up to 12 000 h Have the machine genera...

Страница 76: ...l can t be cleaned thoroughly Have severe clogging removed by an authorised KAESER SERVICE technician 10 4 Air filter maintenance The air filter contains a filter element that can be washed but not re...

Страница 77: ...disconnecting device 10 5 Option H9 Air filter sound damping maintenance Check that all sealing surfaces match each other The use of an unsuitable air filter cartridge can permit dirt to ingress into...

Страница 78: ...ble air filter cartridge can permit dirt to ingress into the pressure system and cause damage to the machine Material Compressed air for blowing out Spares as required Precondition Cut off the electri...

Страница 79: ...can be read off on the oil sight glass Precondition The machine is switched off Fig 31 Checking the oil level 1 Oil sight glass 2 Oil filler and crankcase vent Read off the oil level daily and before...

Страница 80: ...machine and check visually for leaks 10 10 Changing the compressor oil Change the initial charge of oil as specified in table 35 Always drain the oil completely from the compressor block If oil level...

Страница 81: ...ary 4 Switch off the machine and check for leaks The compressor oil has become milky white It is contaminated with condensate Change the oil immediately Contact immediately KAESER SERVICE if condensat...

Страница 82: ...ef valve anticlockwise until air blows off 3 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...

Страница 83: ...user s venting valve are given in chapter 6 6 10 13 Solenoid valve maintenance Prior to any work requiring the opening of the pressure system the machine must be fully isolated from the compressed ai...

Страница 84: ...ve 2 Undo the screw and carefully remove the coil 3 Clean the armature and piston Change the spring if damaged or worn 4 Reassemble the solenoid valve and fix the connecting socket 5 Open the user s s...

Страница 85: ...visually check for leaks 10 14 Cylinder head and valves Material Compressed air for blowing out Cleaning cloths Brush Spares as required 10 14 1 Checking cylinder head and valves To check the valves f...

Страница 86: ...asket and tighten the screws diagonally The tightening torque for the cylinder head screws is given in the following table Compressor block Tigthening torque MA Nm Low pressure cylinder head High pres...

Страница 87: ...e and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 39 Logged maintenance tasks 10 Maintenance 10 15 Documenting maintenance and service work No...

Страница 88: ...sumable parts and operating fluids materials may damage the machine or impair its proper function Personal injury may result from damage Use only original parts and operating fluids materials Have an...

Страница 89: ...AESER spares Increased legal certainty as all regulations are kept to It make sense to sign a KAESER AIR SERVICE maintenance agreement Your advantage lower costs and higher compressed air availability...

Страница 90: ...g device pressure gauge 1 Allow the machine to completely 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...

Страница 91: ...AESER if you intend to transport the machine in freezing temperatures Precondition Transport only by forklift truck or lifting gear only by personnel trained in the safe transportation of loads Ensure...

Страница 92: ...ifting gear 2 Use the lifting gear correctly and lift the machine carefully 12 5 Disposal When disposing of a machine drain out all liquids and remove dirty filters Precondition The machine is decommi...

Страница 93: ...nnex 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 24 E Assembly and operating manual 2 stage piston compressor EPC 2 G...

Страница 94: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 84 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

Страница 95: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram No 9_5753 24 E Assembly and operating manual 2 stage piston compressor EPC 2 G 85...

Страница 96: ...13 2 Dimensional Drawing 13 Annex 13 2 Dimensional Drawing 86 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

Страница 97: ...ge ndert werden Status Dokument TZD Bezeichnung Freigeg Bearb Gez Original Blatt Sprache Name Datum Ma stab Projektion nderungs Nr D F R E I G E G E B E N Abmessungen u Anschlussma e WETTERMANN1 WETT...

Страница 98: ...ANN1 WETTERMANN1 27 05 2013 27 05 2013 EPC 1 G H12 H13 22 04 2013 2 von 3 Dokument TZM 10246364 D 00 A3 Stand 12 11 2012 10246364 D 00 N H1 O F H1 G H1 O M B G C E M H9 M H10 H10 H9 C5 H1 A C5 K D Z L...

Страница 99: ...n u Anschlussma e WETTERMANN1 WETTERMANN1 WETTERMANN1 27 05 2013 27 05 2013 EPC 1 G H12 H13 22 04 2013 3 von 3 Dokument TZM 10246364 D 00 A3 Stand 12 11 2012 10246364 D 00 A Z Z D B O F E G C N F H1 O...

Страница 100: ...13 Annex 13 2 Dimensional Drawing 90 Assembly and operating manual 2 stage piston compressor EPC 2 G No 9_5753 24 E...

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