SERVICE MANUAL

Booster Model: N 501 --- G

10 --- 13 bar / 40 bar

GL---Nr.: N501---G---1.2169.30281---02 V2

Part No.: 1.2169.30281 Serial No.: ............................................... Manufacturer:

KAESER KOMPRESSOREN GmbH

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

1   *  

Table of Contents
Chapter --- Page

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 ------------------1 1 1 1 2 2 2 3 3

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5

2.1 2.2 2.3 2.4 2.5 2.6 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Notes on Accident Prevention Regulations . . . . . . . . . . . . . . . . . . . . . . . Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 2 2 2 ------------5 5 6 7 7 7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.1 3.2 3.3 3.4 Correct Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 3 --------8 8 8 8

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.1 4.2 4.3 4.4 4.5 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport with a Lift Truck or Fork ---lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4 4 4 ----------9 9 10 10 10

Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11

5.1 5.2 5.3 5.4 5.5 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Permissible cut ---in period (ED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of the Base---Mounted Booster Package . . . . . . . . . . . . . . . . . . . . DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 5 5 5 ----------11 11 12 13 15

Table of Contents
Chapter --- Page

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16
6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.6 6.7 6.8 6.9 6.9.1 6.9.2 6.9.3 6.9.4 Prevention of thermal problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection to the low pressure air main 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection to high pressure network 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the Antivibration Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . Compulsory Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor overload trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nonreturn valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 ------------------------------16 16 17 18 18 19 20 21 21 22 25 25 25 25 25

Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26

7.1 7.2 7.3 7.3.1 7.3.2 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Oil Level Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting after a shutdown caused by low oil level . . . . . . . . . . . . . . . . . . . . . . . . . Setting up the float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 7 7 7 ----------26 26 27 27 27

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.1 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faultfinding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor runs continuously, discharge pressure not reached . . . . . . . . . . . Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor unit squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 8 8 8 8 8 8 8 8 --------------------29 29 29 29 30 30 30 30 31 31

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 32
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Maintenance and Repair Work Regulations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Maintenance of the Prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Oil Level and Topping Up (Compressor Block) . . . . . . . . . . . . . . . Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change the oil filter in the crankcase vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or Renew the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or Renew the Nonreturn Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean or Renew the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 9 9 9 9 9 9 9 ------------------32 33 33 34 35 36 37 38 39

ii

Table of Contents
Chapter --- Page

9.10 9.11 9.12 9.13 9.14 9.15 9.15.1 9.15.2 9.16

Checking the V---Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tensioning the V---belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V---Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance of the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning or Changing the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check or Renew the Cylinder Heads and Valves (Compressor Block) . . . . . . .

9 9 9 9 9 9 9 9 9

-------------------

40 40 41 41 42 43 43 44 44

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45

10.1 10.2 Service Parts and Expendable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 47
11.1 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 47

iii

Technical Specification
1
1.1

Technical Specification
Booster unit
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 501 --- G Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 bar Maximum permitted pressure ratio . . . . . . . . . . . . . . . . . . . . . 4:1 (see permitted duty cycle, chapter 5.3) Total weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 kg Diagrams: Dimensionel drawing . . . . . . . . . . . . . . . . . . . . . . . K1.2169.30281 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --P & I flow diagram . . . . . . . . . . . . . . . . . . FKKN501---GS---00023 (Pipework and Instrument flow diagram)

1.2

Sound Pressure Level

Operational state of the compressor unit: Full load, the compressor unit runs at: rated speed, rated pressure, rated capacity. Setting up conditions: Free field measurement Measurement to CAGI/PNEUROP PN8 NTC 2.3: Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 dB (A)

1.3

Compressor Block
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 501 Fore pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 13 bar Theoretical inlet capacity . . . . . . . . . . . . . . . . . . . . . 5500 --- 7000 l/min Free air delivered at 40 bar gauge working pressure . . . . . . . . . . . . . 4208 --- 5670 l/min Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . . 40 bar Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 990 min ---1 Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 l Oil top ---up quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,37 l

1.4

Drive Motor
Three---phase motor 400 / 690 V Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,5 kW Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 min ---1 Enclosure protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 54 Max. switching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 per hour

1 --- 1

Technical Specification
1.5 Power Supply
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 / N / PE Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Possible starting systems Star--Delta 7' at 400 V power supply Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 A Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 50 A Supply cable core cross---section (multicore) . . . . . . . . . . 4 x 10 mm2 Direct-- online ' at 400 V power supply Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 A Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 63 A Supply cable core cross---section (multicore) . . . . . . . . . . 4 x 16 mm2 Direct-- online 7 at 690 V power supply Maximum rated current IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A Maximum mains fusing (slow or gl) . . . . . . . . . . . . . . . . . . . . . 35 A Supply cable core cross---section (multicore) . . . . . . . . . . . 4 x 6 mm2

1.6

Safety Valve Setting

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 bar

1.7

Installation Conditions
Attention! Ensure that the compressor package is level. The floor must be solid with good loading characteristics. The weight of the package is given in chapter 1.1.

Maximum altitude of installation . . . . . . . . . . . . . . . . . . . . . . 1000 m Minimum ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 5 C Maximum ambient temperature * . . . . . . . . . . . . . . . . . . . . . . . 35 C * At elevated ambient temperatures the diagram in chapter 5 showing maximum cut ---in duration ED must be taken into consideration. m

Minimum recommended room size (floor area x height) . . . . . . . . . . . . . . . . . . . . . . . . . . 35 m2 x 3,5 Ventilation (natural ventilation)

Inlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 m2 Outlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 m2

1 --- 2

Technical Specification
1.8 Oil Recommendations
Under normal operating conditions (see chapter 1.7) fill with oil of viscosity class VG 150 to DIN 51 562, group VDL. Recomended compressor oils to DIN 51 506, group VDL Suppliers AGIP ANTAR Type of oil AGIP DICREA150 ELF DACNIS P 150 BARELF AL 150 ARAL Motanol HE 150 AVILUB VDL 150 BP Energol RC 150 Actro EP VDL 150 Xenic EP VDL 150 DEUTZ OEL VDL150 ELF DACNIS P 150 BARELF AL 150 VERDICHTEROEL 3022 N FINA EOLAN AC 150 RENOLIN 505 RENOLIN VDL 150 DD Mobil Rarus 429 Shell Corena l H 150 D Shell Corena l H 150 Shell Corena l P 150 TOTAL Cortusa 150

ARAL AVIA BP DEA

DEUTZ ELF

ESSO PURFINA RENOLIN

MOBIL OIL SHELL

TOTAL

1.9

Dimensional Drawing
(see following page)

1 --- 3

Safety
2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting this compressor into operation and before carrying out any maintenance.

2.1

Explanation of Symbols and References

This symbol is placed before all instructions concerning safety where danger to life and limb can occur during work. It is especially important that these instructions are observed and that extreme care is taken. For their own protection, inform other users of all instructions concerning safety. Observe the general safety and accident prevention regulations as well as the instructions laid down in this service manual. Attention! This symbol is placed by text where considerable attention must be paid to directives, regulations, instructions and the correct sequence of work so that damage and/or destruction of the compressor block is prevented. This symbol identifies environmental care measures.


-

This symbol indicates operations and actions to be carried out by the operator or service technician. This bullet identifies listings.

Explanation of the warning label on the compressor unit: Warning: Do not touch hot surfaces.

2.2

General Notes on Accident Prevention Regulations

European Standards must be complied with when carrying out installation, operation, maintenance and repair of compressor units. Valid national regulations and standards must be complied with for those European Standards that are not yet incorporated into national legislation. Users of compressor units located outside the jurisdiction of European Standards are obliged to comply with the valid safety and accident prevention regulations concerning the compressor unit in the country of use. If necessary, corresponding measures must be taken to ensure compliance with national regulations before the compressor is put into operation. We also recommend observation of the following: Allow no open flame and flying sparks in the place of installation. During any necessary welding near compressors ensure that sparks or high temperatures cannot cause fire or explosion. Ensure that the inlet air to the compressor is clean and free of damaging components. The ambient temperature should not rise above or fall below the limits defined in chapter 1.7. If this is the case, special measures must be agreed between the manufacturer and the user. The oil change must be carried out according to the service manual, or at least once annually.

2 --- 5

Safety
2.3 Electrical Safety
Attention! The electrical system of a compressor unit must comply with the provisions of the European Standards EN 1012 -- 1 and EN 60204 -- 1) and, if necessary, with the local electricity supply authority regulations. Compressor units must be fitted with a main isolating device, the operation of which determines the start and end of the energy supply. Main isolating devices can be main switches or plug and socket connections. For this reason the following measures must be taken at the place of installation: Compressor units fitted with a drive motor of drive power 3 kW or more and a current rating of 16 amperes or more must be fitted with a lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses. The main switch must be designed according to the maximum rated current I N (see chapter 1.5). See chapter 1.5 for details of the cable cross-- sections and mains fuses. Compressor units fitted with a drive motor of drive power less than 3 kW and a current rating of less than 16 amperes may be fitted with a mains plug connection.

2 --- 6

Safety
2.4 General References
Attention! The base mounted package may only be put into operation when all required protective and safety devices are in place and operational (see chapter 6.9). Work on power driven systems may only be carried out by trained or specialised personnel. Work on the electrical system and equipment of the compressor unit may only be carried out by a skilled electrician or by instructed personnel under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Before work is carried out on electrical systems, carry out the following measures in the sequence shown. 1. Switch off all phases. 2. Ensure the unit cannot be switched on again 3. Check that no voltage is present Vent or shut off pipework under pressure if not stated otherwise in the service manual. Attention! Any alterations or reconstruction carried out without consultation with and without the previous consent of KAESER will invalidate the warranty.

2.5

Spare Parts
Safe and reliable operation of the compressor is guaranteed only by KAESER original spare parts.

2.6

Environmental Protection
Condensate drainage Condensate accumulating during compression must be drained via a suitable draining system and collected in disposal canisters. The condensate must be disposed of according to environmental regulations. Operational and repair materials, used parts Dispose of all used materials and parts accumulating during operation, maintenance and repair of the compressor unit according to environmental care regulations!

2 --- 7

General
3 General
Attention! The service manual must always be available at the compressor s place of use.

3.1

Correct Use of the Compressor

The compressor is intended solely for the purpose of generating compressed air. Any other use is considered incorrect. The manufacturer cannot accept liability for any damage caused by such incorrect use; the user alone is liable for any risks incurred. Correct use of the compressor also encompasses compliance with the installation, removal, commissioning, operational and maintenance conditions laid down by the manufacturer. This compressor package may only be used for industrial purposes.

3.2

Incorrect Use
Never direct compressed air toward persons. Compressed air is a concentrated form of energy and as such is dangerous to life.

3.3

Compressed Air Treatment

Never use compressed air for breathing purposes and production methods where the air has direct contact with food without subjecting the compressed air to additional treatment.

3.4

Copyright
The copyright of this service manual is the property of the KAESER Company. This service manual is intended for operating personnel, maintenance personnel and supervisory personnel use only. It contains instructions and technical diagrams that may not be copied, either completely or partly, distributed or evaluated by unauthorised persons for the purpose of competition, or divulged to any other third party.

3 --- 8

Transport
4
4.1

Transport
Transport Instructions
Never transport the compressor other than vertically to prevent damage to the compressor block. See chapter 1.3 for details of the weight.

4.2

Transport with a Lift Truck or Fork ---lift Truck

Always mount the compressor on a suitable transport medium (pallet) when transporting with a fork ---lift truck or lift truck. Attention! Never drive directly underneath the compressor and lift.

4 --- 9

Transport
4.3 Transport Using a Crane
Attention! If the compressor unit is transported by a crane the safety regulations concerning lifting appliances must be observed. Do not stand underneath hanging loads. Do not exceed the max. permitted lifting weight of the lifting appliance. Always use a sling when transporting the compressor unit with a crane. Attention! Take care not to damage parts of the compressor when lifting with the sling.

4.4

Packaging
A decisive factor concerning the type of packaging is the transport route. The packaging conforms to the packaging regulations laid down by the German Federal Association of Wood, Pallet and Export packaging (HPE) and by the German Machinery and Plant Association (VDMA), if not otherwise contractually agreed.

4.5

Storage
Always store the compressor, whether packaged or not, in an enclosed, dry space. The ambient temperature may not exceeds the limits of --- 25 C and + 60 C.

4 --- 10

Construction and Operation

5 Construction and Operation
Items in ( ) refer to components with item number in the schematic diagram of the compressor unit (see chapter 5.4).

5.1

Principle of Compression
This booster compressor is an air cooled, oil lubricated compressor using the principle of single stage compression Compressed air from an air main is drawn in through the inlet port (1) and the collector pipe (3) to the compression chamber of the compressor block (2). This compressed air is drawn in via the valve plate in the cylinder head during the downward motion of the piston from the top to the bottom dead centers. After the piston has reached the bottom dead center position the compressed air is boosted within the cylinder by the upwards motion of the piston. Simultaneously the inlet valves in the valve plate close and the discharge valves open. The boosted compressed air flows via an aftercooler pipe (4) to the compressed air outlet (5).

5.2

Short Description
The compressor block is driven by an electric motor (9) via a V---belt. The cylinders are arranged as a V. The belt pulley on the compressor shaft is designed as a cooling fan and provides the cooling air necessary to cool the cylinders. Cooling fins on the cylinders and heads dissipate the heat generated by compression. The crankshaft is supported by roller bearings; the connecting rods are supported by needle and roller bearings. The cylinder walls, pistons, crankshaft and connecting rods are automatically splash lubricated. Two valves are installed to ensure an unloaded start of the booster. A solenoid valve (13, closed when de---energised) prevents backflow of the the compressed air to be boosted when the booster stops. During this stopped period the second solenoid valve (14, open when de---energised) vents the pressure line between the inlet valve and the check valve to be installed by the user.

5 --- 11

Construction and Operation

5.3 Permissible cut---in period (ED)

Compression ratio [PB(a)/P1(a)]

max.

Ambient temp. 30 C, inlet temp. 35 C Ambient temp. 40 C, inlet temp. 45 C Ambient temp. 45 C, inlet temp. 50 C

Example
3.4
Up to 100% duty cycle Up to 80% duty cycle Up to 65% duty cycle

Final temperature [ C]
The permissible cut ---in period (ED) of the booster is related to the compression ratio (discharge pressure PB absolute / initial pressure P1 absolute, the ambient temperature and the compressed air inlet temperature (see diagram). Example: Initial pressure 11 bar (g) Discharge pressure 40 bar (g) Compression ratio: 41 bar (abs) / 12 bar (abs) = 3.4 Ambient temperature 40 C, inlet temperature 45 C Results ijn a duty cycle (ED) of 80 %.  Duty cycle (ED) = Duty cycle (ED) is the portion of the total operatin cycle that the unit is under load. Time under load Time under load + stationary time

ED [%] =

x 100 %

Non ---permissible range

5 --- 12

Construction and Operation

5.4 Components of the Base ---Mounted Booster Package
14 9 7 12 6 10 2 4 3 13 1 11

5 --- 13

Construction and Operation

1 Air inlet connection 2 Compressor block compresses the inlet air 3 Collector pipe collects and calms the compressed air 4 Aftercooler collects and calms the compressed inlet air and dissipates heat via the cooling fins 5 Compressed air outlet outlet air connection 6 Oil return line the high pressure in the crankcase causes turbulence in the oil and forces it through the oil return line to the oil collection bottle 7 Oil collection bottle collects the oil from the crankcase 8 Safety valve protects the compressor against excess of max. permissible pressure 9 Electric motor 10 Oil filler with crankcase venting and oil filter 11 Oil level sight glass 12 Oil drain plug 13 Solenoid valve (closed when de ---energized) 14 Solenoid valve (open when de ---energized)

5 --- 14

Construction and Operation

5.5 DUAL Control
p max p min

Pressure

2 3 t1

4 t2

Full load Motor power

Off ---load running Standstill Time

In DUAL Control (combined off---load running and intermittent control) the compressor normally runs at full -- load and off-- load running or standstill. Operation is controlled by a pressure switch within set limits (see chapter 6.9.2) between full -- load and off-- load running. If the compressor runs for longer than a preset time period, (1) to (2) e.g. t1 = 6 min, in off---load running, the electric motor switches off completely (2). When the low pressure switching point p min (3) is reached the motor will restart automatically. The pressure now rises to the high switching point p max (4) and the compressor runs in off---load running. Should, however, the pressure drop within a shorter time period (4) to (5) e.g. t2 = 3 min again to p min (5), the compressor will automatically switch from off---load running to full--load.

5 --- 15

Installation
6
6.1

Installation
Prevention of thermal problems
Ensure adequate air inlet and outlet appertures in the room (see chapter 1.7). Correct location of the apertures (constant airflow). Correct machine positioning (all machines must be able to draw in cool fresh air). Hot discharge air must leave the room directly by the shortest path. Do not exceed the permitted duty cycle .

6.2

Installation instructions
To ensure sufficient ventilation of the compressor unit, a minimum distance to the wall, a minimum room size and the recommended sizes of the cooling air inlet and discharge apertures 1.7) must be kept to. Opening the door in smaller rooms will not influence the compressor cooling air flow to a any degree if the air flowing through the door takes the shortest route to the cooling air discharge aperture without flowing across the compressor unit. Safe operation of the compressor unit is only ensured if the ambient temperature limits (see chapter 1.7) are kept to.

Exhaust opening

1200

500 Inlet opening Dimensions in mm

6 --- 16

Installation

6.3

Installation instructions
Install the booster unit according to the following schematic to ensure its reliable operation with other components. Ensure that shut ---off valves (ball valves) are installed at the required points to allow maintenance to be carried out. Attention! If the booster is installed together with other plant (compressors, refrigeration dryers, etc.), then under no circumstances may the hot cooling air discharged from that other plant be directed to the cooling air inlet end of the booster!

6 --- 17

Installation
6.4 Compressed Air Connection
The connections for the air inlet and outlet are identified in the dimensional diagram (see chapter 1.9).

Low pressure main 1

5 --- 13 bar
Low pressure consumers

High pressure main 2

up to 45 bar

Fine filter 1 Prefilter Separator High pressure consumers

Fine filter 2

Rotary screw compressor

Air dryer 1

Air receiver 1

Booster

Air receiver 2

Air dryer 2

Option

6.4.1

Connection to the low pressure air main 1 The connection to the booster unit to the low pressure air main must be made with a pipe connection installed in the form of a swans neck. The prefilter, which is absolutely essential for reliable operation of the booster unit ensures that dust and condensate---free air is drawn in. The connection between the prefilter and the booster unit must be made with a flexible hose. Specified compressed air inlet quality for the booster units: Moisture: max.100% (drip free) Particles: %1mm

If there is no dryer between the compressor and receiver in the low pressure air main then it is imperative that the prefilter is fitted with an automatic drain valve (ECO DRAIN). Furthermore, the booster unit must run in idle for approximately three minutes before shutdown to ensure that the inlet pipe is dry (idle control must be fitted).

6 --- 18

Installation

1 2 4 3 5

B A

A Low pressure air consumer B Booster unit (compressed air inlet) 1 2 3 4 Compressed air line (low pressure) Supply line with swan neck Hose line Pre ---filter

5 Connection to low pressure compressed air network = Compressed air inlet to booster B

6.4.2

Connection to high pressure network 2 The connection from the booster package to the high pressure network must be made with a flexible hose.

1 Connection to high pressure compressed air network = Booster air outlet

6 --- 19

Installation
6.5 Fitting the Antivibration Mounts
The antivibration mounts supplied (as a separate pack fixed to the compressor block) must be fitted before the compressor package is first put into operation. Attention! Always use lifting belts to lift the compressor package. Follow the instructions in chapter 4.3. The compressor package can tip because of its high point of gravity and its own weight.

5 4 2 3

1 Antivibration mount 2 Oblong hole 3 Washer

 

4 5

Spring washer Hexagonal nut

Lift up the compressor package with a lifting belt. Observe the instructions in chapter 4.3. Fit the antivibration mounts (1) with washer (3), spring washer (4) and hexagonal bolt (5) to the feet of the compressor package.

6 --- 20

Installation
6.6 Power Supply
The connection to the power supply and the protective measures necessary are to be carried out to the provisions of the European Standards EN 1012 -- 1 and EN 60204 -- 1 and to the regulations of the local Electricity Supply Authority by an authorized electrician. Attention! For this reason, the following measures must be carried out at the place of installation: Compressor units fitted with a drive motor of drive power 3 kW or more and a current rating of 16 amperes or more must be fitted with a lockable main switch (see EN 60204 -- 1, para. 5.3) and mains fuses. Compressor units must be fitted with a main isolating device, the operation of which determines the start and end of the energy supply. Main isolating devices can be main switches or plug and socket connections. The main switch must be designed according to the maximum rated current I N (see chapter 1.5). Compressor units fitted with a drive motor of drive power less than 3 kW and a current rating of less than 16 amperes may be fitted with a mains plug connection. Attention! The supply cable and fuses are selected to DIN VDE 0100 Part 430 and 513 for an ambient temperature of 30 C. Under other operating conditions such as a higher ambient temperature or longer supply cables (longer than 50 metres) the cross-- section of the supply cables and the fuses must be checked and selected according to DIN VDE 0100 and to the regulations of the local Electricity Supply Authority. See chapter 1.5 for details of the cable cross-- sections and mains fuses.

6.7

Control
A controller conforming to EN 60 204 must be provided for the connection to the power supply. The compressor is fitted with a solenoid valve (230 V) that allows an unloaded start via a controller in direct ---on ---line or via a star---delta starter. A second solenoid valve (230 V) that is closed when de---energized is fitted in the inlet line. This valve prevents compressed air from flowing into the block when the compressor is shut down. The electrical components required must be designed for the corresponding motor power (see chapter 1.4) and the selected starting mode (see chapter 1.5). The motor, pressure switch and the solenoid valve must be activated by the controller. The solenoid valve must be activated such that the solenoid valve first closes when the motor has run up to normal operating speed. The automatic oil level monitoring must also be supervised by the controller. Ensure that the setting is on the red arrow, i.e. the contact is closed when the oil level is sufficient. The components are to be arranged on the compressor as shown in the accompanying P & I flow diagram.

6 --- 21

Installation
6.8 Pipe and Instrument Flow Diagram (P & I Diagram)
(see following pages)

6 --- 22

Installation
6.9 Compulsory Safety Equipment
Attention! Safety and regulating equipment must be installed by the user to ensure safe operation of the compressor.

6.9.1

Motor overload trigger To ensure that three---phase motors are cut ---out under conditions of fluctuating voltage, they may only be driven with a correctly adjusted motor overload trigger. Attention! The warranty is invalidated if the compressor is operated without motor overload trigger or overload protection switch.

6.9.2

Pressure switch A pressure switch must be fitted for the regulation of the compressed air demand. This pressure switch regulates the compressor between the cut ---out and cut ---in pressures.

6.9.3

Nonreturn valve To prevent the compressed air from flowing back into the compressor block, a nonreturn valve must be fitted to the air receiver. Attention! The sizing of the nonreturn valve depends upon the maximum working pressure (see chapter 1.3) and the cross-- section of the connection to the air main (see dimensional diagram) from the compressor.

6.9.4

Working pressure gauge A pressure gauge must be provided to monitor the gauge working pressure. This pressure gauge must be selected according to the maximum gauge working pressure (see chapter 1.3) of the compressor.

6 --- 25

Initial Start
7
7.1

Putting into Operation

Points to be Observed before Putting into Operation
Every compressor package is given a test run in the factory and carefully checked before shipment. The test run confirms that the compressor package conforms to the specification data and runs perfectly. However, independent of the checks made at the factory, the compressor package could be damaged during transport. For this reason, we recommend that it is examined for such possible damage. Observe the compressor package carefully during the first hours of operation for any possible malfunction. Attention! Work on power driven systems may only be carried out by trained or specialised personnel. Work on the electrical system and equipment of the compressor package may only be carried out by a skilled electrician or by instructed personnel under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Attention! Important functional components in the compressor package such as solenoid valves and safety valves are set up and fitted at the factory to precise setting up regulations. Changes are not permitted without previous consultation with KAESER. The solenoid valves and the safety valves are spring loaded. Points to be observed before starting the compressor unit: ANY NON -- OBSERVANCE OF THESE OR OTHER REFERENCES (WARNING; ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. The compressor unit restarts automatically after a power failure provided the air main pressure is lower than the cut-- out pressure level set on the air main pressure switch. It is expected that the operator employs safe working methods and that all valid and, if necessary, all local operating and safety regulations are complied with when operating the compressor unit. The user of this compressor unit is responsible for its safe operating condition. Do not operate this compressor unit in spaces where high dust pollution, poisonous or inflammable vapours or gases could exist. Do not connect the compressor unit to a supply voltage other than that stated on the nameplate. Do not install the compressor unit in a space subject to freezing temperatures, whereby the air temperature conditions at the compressors air inlet must be complied with (see chapter 1.7). Check the level of the oil in the compressor block. If necessary, top up according to the oil recommendations (see chapter 1.8).

7.2

Direction of Rotation Check

Check the direction of rotation of the compressor block by switching it on for a short period. If the direction of rotation does not coincide with the arrow located on the fan guard, change over terminals L1 and L2.

7 --- 26

Initial Start
7.3 Automatic Oil Level Supervision
The oil level supervision is installed at the factory using a quiescent (normally closed) sensing contact. This sensing contact is set up with the red arrow. Type of contact Normally closed Oil level rising falling 7.3.1 Starting after a shutdown caused by low oil level If the minimum oil level is reached the automatic oil level supervision shuts down the compressor and an alarm lamp is illuminated.  Switch off the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main power supply switch) to prevent an accidental compressor start.   7.3.2 Top up with oil (see chapter 9.4). Switch on the compressor (see chapter 8.1). Electrical contact closing opening

Setting up the float switch The float switch is set up at the factory such that the compressor is shut down when the minimum permissible oil level is reached (lower mark on the oil level sight glass). At this level the point of the red arrow on the sensing contact is visible for 2 mm.

7 --- 27

Initial Start

A
Red arrow

Contact closed at max. oil level

A A --- A
Oil level maximal minimal Oil

Contact open at min. oil level

6 --- 7 2

--2

_
2

max. min.
Dimensions in mm

1 2 3 4

Float Locking screw Red arrow Sensing contact

The switching point can be adjusted slightly by moving the sensing contact (4). If the switching point is to be set above the minimum permissible oil level move the sensing contact (4) upwards so that the point of the red arrow (3) is visible for less than 2 mm. Attention! The sensing contact can only be moved upwards for a maximum of 2 mm. This is to avoid unnecessary shutdown of the compressor when sufficient oil is available.

Switch off the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main power supply switch) to prevent an accidental compressor start.

 

Loosen the locking screw (2) and slide the sensing contact (4) upwards. Tighten the locking screw (2) again.

7 --- 28

Operation
8
8.1

Operation
Starting and Stopping the Compressor Unit
Switch the compressor unit on and off with the main power supply switch. Starting the compressor unit  Switch on the main power supply switch (see chapter 2.3). Check for correct direction of rotation when starting the compressor unit (see chapter 7.2).

Attention!

Stopping the compressor unit  Switch off the main power supply switch.

8.2

Faultfinding and Removal

General safety regulations (see chapter 2) and local safety regulations must be complied with during faultfinding and removal procedures. Starting after a defect: See chapter 7 Putting into Operation. Explanation of symbols for the following fault diagnosis: % 1 --- have checked by a specialist. % 2 --- contact KAESER customer service department.

8.2.1

Compressor does not start Possible cause: No motor power supply, fuses blown. Remedy: Replace the fuses; % 1.

8.2.2

Compressor starts with difficulty Possible cause: Solenoid valve not opening Remedy: Check the electrical connection, clean or change the valve (see chapters 9.15.1/9.15.2) Renew the bearings or fit an exchange compressor Change the piston and cylinder (see chapter 9.16) Check the power supply (fuses); % 1 Reduce the oil level to the maximum mark on the oil level sight glass (see chapter 9.4

Damaged bearings Piston seized (no oil or wrong oil) Power supply fault (2---phase running) Oil level too high

8 --- 29

Operation
8.2.3 Compressor overheating Possible cause: Ambient temperature too high (over 40 C). Wrong direction of rotation (observe the direction arrow). The fan cannot draw in air freely. Valve plate leaking, coked or the valve reeds are broken. 8.2.4 Remedy: Lower the ambient temperature (see chapter 1.7). Change over L1 and L2 terminals (see chapter 7.2); % 1. Ensure that inlet air is available for the fan. Check, decoke or renew valve plate; % 1 and % 2.

Compressor runs continuously, discharge pressure not reached Possible cause: Valve plate gasket defective or wrongly fitted Valve plate valves coked up or defective Pressure losses within the unit Air demand higher than the capacity of the compressor Solenoid valve blowing off constantly, coil burnt out or defective actuation Remedy: Fit new gaskets Clean or change the valves (see chapter 9.16) Brush soapy water on piping and fittings, seal leaks or renew leaking parts Increase the size of the compressed air supply Check the solenoid valve, clean the valve or change the coil

8.2.5

Whistling noises at the cylinder head Possible cause: Loose cylinder head bolts or defective gaskets. Remedy: Tighten the bolts or renew the gaskets; % 1 and % 2.

8.2.6

Safety valve blowing off prematurely Possible cause: Safety valve blows, even though the cut --out pressure is not yet reached. Defective valve spring. Safety valve was opened, dirt particles stuck in valve seat. Remedy: Check that the pressure gauge functions correctly, replace if necessary. Check the pressure setting. Renew the safety valve; % 1. Open the safety valve completely for a short period to allow it to blow itself clean.

8 --- 30

Operation
8.2.7 Oil consumption of compressor too high Possible cause: Viscosity of oil too low. Defective crankcase venting plug. Piston rings worn or damaged. Piston rings worn or damaged after only a short period. Remedy: Fill with correct oil (see chapter 1.8); % 1. Clean or renew the crankcase venting plug; % 1. Renew piston rings and cylinder; % 2. Renew piston rings and cylinder; % 2. (ensure that the inlet air is clean, e.g. by using an air filter with a higher grade of filtration).

8.2.8

Compressor unit squealing Possible cause V---belt(s) slipping Sealing ring on the shaft of the fan pulley running dry Remedy Tension the V---belt(s) (see chapter 9.10) Oil the sealing ring

8 --- 31

Maintenance
9
9.1

Maintenance
Maintenance and Repair Work Regulations:
Attention! Work on power driven systems may only be carried out by trained or specialised personnel. Work on the electrical system and equipment of the compressor unit may only be carried out by a skilled electrician or by instructed personnel under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Before any maintenance work is carried out on the compressor unit break the power supply by operating and locking out the main isolating device (mains supply switch or mains plug, see chapter 2.3) to prevent an accidental compressor start. If work is to be done on the pressurised pipework of the compressor the pipework must be vented beforehand. Before starting the compressor again ensure that no maintenance personnel are working on the compressor and that all covers are fitted. To start the compressor see chapter 8.1. Attention! Always check and tighten all screwed fittings that were removed or loosened during maintenance and repair work. Dispose of all used materials and parts accumulating during operation, maintenance and repair of the compressor unit according to environmental care regulations!

9 --- 32

Maintenance
9.2 Regular Maintenance
Period daily 24 hours after first putting into operation and after changing the V--belt 50 hours after first putting into operation Work to be done check the oil level in the crankcase check the V---belt tension See chapter 9.4 9.10

check all electrical screw connections for tightness and tighten if necessary carry out a compressor oil change

7.1 9.5 9.5 9.7 9.6 9.9 9.10 9.13 9.8 9.15.1 9.15.2 9.16 9.14 9.16

500 hours or at least anually

carry out a compressor oil change * check and clean the air filter * oil filter change check and clean the dirt trap check the V---belt tension check the safety valve check and clean the nonreturn valve * clean the solenoid valve

2000 hours 3000 hours 10000 hours

renew the solenoid valve check the cylinder head and valves for correct function renew the motor bearings carry out a general overhaul of the compressor

* The maintenance interval can vary according to model, installation, cut ---in frequency and the ambient conditions. We recommend that a record is kept of all maintenance work. A sample maintenance record is provided in chapter 11.1.

9.3

Regular Maintenance of the Prefilter

Period Depending on filter Work to be done clean the prefilter in the inlet pipe See chapter see manufacturers instructions

Attention!

If the appropriate cleaning regulations are not observed condensate and dusty compressed air could be sucked in that could lead to destruction of the booster package.

9 --- 33

Maintenance
9.4 Checking the Oil Level and Topping Up (Compressor Block)
Check the oil level at the oil level sight glass daily and before each start. Attention! If the oil level has sunk to the lower mark, top up the oil immediately according to the oil recommendations (see chapter 1.8). Never top up to a level exceeding the maximum oil mark on the oil level sight glass. Attention! When topping up the oil always use a strainer or pour the oil directly from the new oil can.

max. min.

1 Oil filler with crankcase venting 2 Oil level sight glass

 Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.  Remove the crankcase venting plug (1) from the oil filler. As the oil must flow through the crankcase first, the maximum oil level is reached after a few minutes have elapsed.

Attention!  

Fill with oil until the maximum oil level mark is reached. See chapter 1.3 for the quantity of oil required for topping up from the minimum mark to the maximum mark. Replace the crankcase venting plug in the oil filler.

9 --- 34

Maintenance
9.5 Oil Change (Compressor Block)
Change the oil with the compressor unit at normal operating temperature. Danger of scalding by hot oil Danger of burns from hot components Change the oil after the first 50 service hours approximately. Change the oil after every further 500 service hours or at least annually. If, under unsuitable operating conditions, condensed water is observed in the oil, recognisable by the milky colour in the oil level sight glass (2), carry out an oil change immediately. See chapter 1.8 for suitable oils.

4 max. min.

2 3 5

1 2 3 4 5


Crankcase venting with oil filter Oil level sight glass Oil drain plug Hose Oil collecting canister
Switch the compressor off (see chapter 8.1). Isolate from the power supply by means of the main switch or by withdrawing the plug and secure against re -- connection to prevent accidental starting.

 

Remove the crankcase vent (1) from the oil filler port. Prepare a container to catch draining oil. Catch the used oil and dispose according to environmental regulations.

  

Remove the oil drain plug (3) and allow the oil to drain into the container. Flush the crankcase with a small volume of fresh oil. Replace the oil drain plug (3). A sieve should be used when refilling with fresh oil unless it is from a new can of genuine Kaeser oil.

Attention! 

Fill with fresh oil (see chapter 9.4).

9 --- 35

Maintenance
9.6 Change the oil filter in the crankcase vent
Pressure in the crankcase produces oil mist that must not be allowed to escape to atmosphere. For this reason, the crankcase is vented through a filter (5) that retains the oil. Under continuous boster operation oil can build up in the crankcase vent to such a level that it cannot run back to the crankcase. A pipe (2) leads the excess oil to a container (3) from which it must be tipoped back into the crankcase. Attention! The booster masy not be operated without a crankcase vent.

The oil filter (5) must be changed every 2000 operating hours.

4 7 1

5 2 6

3 6 1 2 3 4


Crankcase venting with oil filter Hose Oil collecting canister Venting cap

5 6 7

Oil filter O ---ring Spring

Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.

   

Unscrew the hose (2) from the crankcase venting plug (1). Remove the crankcase venting plug (1) from the oil filler. Unscrew the venting cap (4) from the crankcase venting plug (1). Take out the oil filter (5). Dispose of the oil filter in accordance with environmental regulations.

   

Insert the new oil filter (5). Screw the venting cap (4) back into the crankcase venting plug (1) again, checking the correct seating of the spring (7) for the pressure setting. Screw the crankcase venting plug (1) back into the oil filler. Screw the hose (2) back onto the crankcase venting plug (1).

9 --- 36

Maintenance
9.7 Clean or Renew the Air Filter
The filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre. Clean the filter cartridge (3) at the latest after 500 service hours. If the cartridge is heavily contaminated or has been cleaned often, renew the air filter complete.

2 1 3 4 1 2 3 4


Air filter Air inlet Filter cartridge Spring clips

Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.

  

Isolate the compressor from the air main. Close the ball valves at the air inlet and outlet of the compressor (see chapter 6.4). Unscrew the air filter (1) from the collecting pipe. Push back the spring clips (4) and open the filter cap. Clean the filter with diesel fuel in the open air. Observe the regulations concerning the handling of combustible fluids.

Attention!    

Clean the filter cap, especially the sealing surfaces. Wash out the filter cartridge (3) with diesel fuel or clean with a steam jet. When the filter cartridge (3) is dry wet lightly with oil. Screw on the air filter (1), fit the cap. If the cartridge is heavily contaminated or has been cleaned often, renew the air filter complete. Open the ball valves again before putting the compressor back into operation.

Attention!

Attention!

9 --- 37

Maintenance
9.8 Clean or Renew the Nonreturn Valve
The nonreturn valve is fitted to the collecting pipe. It prevents the compressed air from flowing back to the open air during operation of the compressor. Check and clean the nonreturn valve every 500 service hours, if necessary.

2 1

6 5

4 3 1 Nonreturn valve 2 End plug 3 Valve cone



4 5 6

Valve seat Spring Sealing ring

Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.

Isolate the compressor from the air main. Close the ball valves at the inlet and outlet of the compressor (see chapter 6.4). Do not open the end plug in the valve housing until the pressure gauge indicates zero.

   

Unscrew the end plug (2) in the valve housing. Clean the valve cone (3) and valve seat (4). Renew the valve cone (3), the spring (5) and the sealing ring (6) if they are badly worn or damaged. Reassemble in the reverse order. Open the ball valves again before putting the compressor back into operation.

Attention!

9 --- 38

Maintenance
9.9 Clean or Renew the Dirt Trap
The dirt trap prevents contamination of the solenoid valve and the air inlet chamber. If problems occur during off load running or during unloaded start, clean the dirt trap. It must be cleaned at the latest after 500 service hours.

1 2 1

1 1 Plug 2 Strainer
 Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.  Unscrew the plug (1). Do not direct compressed air at the skin or other parts of the body. There is danger of injury. Always wear working gloves or protective goggles.  Remove the strainer (2) and clean by blowing out. If the strainer is very dirty or has been cleaned often it should be renewed.

Attention! 

Screw the strainer (2) and plug (1) back in again.

9 --- 39

Maintenance
9.10 Checking the V---Belt Tension
Check the tension of the V---belt after the first 24 service hours and then again after 500 service hours.  Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.   Remove the belt guard. Press down the V---belt with the thumb.

If the V---belt can be depressed more than 1 to 2 cm it must be tightened.

9.11

Tensioning the V---belt

 Shut down the compressor unit (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.      Remove the belt guard Loosen the hexagonal nuts on the motor mounts. Slide the motor until the V---belt is tight again, i.e. it cannot be depressed more than 1 to 2 cm. Tighten the hexagonal bolts. Fit the belt guard again.

1 Hexagonal nut

9 --- 40

Maintenance
9.12 V---Belt Change
 Shut down the compressor unit (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.        Remove the belt guard. Loosen the hexagonal bolts on the motor mounts. Slide the motor in the direction of the compressor block until the V---belt can be removed over the motor and compressor pulley. Place the new V---belt over the motor and compressor pulley without straining it. Slide the motor in the opposite direction until the V---belt is correctly tensioned. Tighten up the hexagonal bolts. Check the tension after the first four service hours and then again after a further 24 service hours. Tighten, if necessary (see chapter 9.10). Spare V-- belts must be of the same length in each set and absolutely impervious to oil. For this reason we recommend that only original KAESER V-- belts are used. V-- belts may only be replaced as a set.

Attention!

Attention! 

Fit the belt guard again.

9.13

Checking the Safety Valve

If the maximum permissible gauge working pressure at the discharge end is exceeded, the safety valve (2) opens and blows off the excess air to protect the compressor unit and the consumers connected to the air main. To prevent the valve seat from sticking, open the safety valve every 500 service hours or at least annually.

1 Ring 2 Safety valve

Attention!  Always wear ear muffs during the safety valve check because of the extremely loud noise caused when the valve opens.

Shut down the compressor unit under load (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor start.

9 --- 41

Maintenance
 Pull the ring (1) on the safety valve (2) until the valve opens and then release the ring again. A defective safety valve must be renewed complete. Adjustment of the safety valve setting and removal of the seal is forbidden and invalidates all liability.

Attention! Attention!

9.14

Maintenance of the Motor Bearings

The motor bearings are permanently greased. Under normal operating conditions, with ambient temperatures around 25 C, the motor bearings should be renewed approximately every 10 000 service hours. The wear on the bearings increases with higher ambient temperatures. With very high ambient temperatures of around 35 C renew the bearings approximately every 6000 hours. Change the motor bearings every 3 years independent of service hours. The bearings must be changed by KAESER-- Service when the above maintenance is due.

Attention!

9 --- 42

Maintenance
9.15 Cleaning or Changing the Solenoid Valve
If the solenoid valve leaks during operation the cause is often dirt settling on the plunger or the solenoid core. Clean the solenoid valve every 500 service hours and change after 2000 service hours. 9.15.1 Cleaning the solenoid valve  Shut down the compressor (see chapter 8.1) Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor unit start. Attention! Take care not to lose individual parts when taking out the coil.

7 8

1 2 3 4 5
    

Solenoid valve Cylinder head screw Coil Solenoid core Spring

6 7 8 9

Spring Plunger Lip seal Direction of flow

Unscrew the cylinder head screws (2). The electrical cable must not be removed from the coil when taking off the solenoid valve. Disassemble the solenoid valve (1) into its individual parts. Clean the plunger (7) and the solenoid core (4). Grease the lip seal (8) with Vaseline. If the springs and seals are badly worn or damaged they must be changed. Take care that the individual parts are assembled in the correct order (see illustration) when reassembling the solenoid valve.

Attention! 

Reassemble in the reverse order.

9 --- 43

Maintenance
9.15.2 Changing the solenoid valve  Shut down the compressor (see chapter 8.1). Break the power supply by operating and locking out the main isolating device (main switch or mains plug) to prevent an accidental compressor unit start. Attention! Isolate the booster package from the air main by interrupting the supply of compressed air (by closing the ball valve) when changing the solenoid valve on the inlet side.

2 1 1 2 1 1

1 1 Pipe fitting 2 Cable

   Open the pipe fitting (1). Remove the electrical cable (2) from the solenoid valve by removing the valve plug. Electrically connect the new solenoid valve. Take care that the valve is installed with the correct direction of flow (see chapter 9.15.1 item 9).

Attention! 

Fit the solenoid valve and gasket into the piping.

9.16

Check or Renew the Cylinder Heads and Valves (Compressor Block)

Check the cylinder heads and the valves for correct function after 3000 service hours. Attention! If faults are obvious on the cylinder head or the valves, these parts must be repaired or renewed by KAESER Service.

Have the compressor generally overhauled by KAESER Service after 10000 service hours.

9 --- 44

Spare Parts and After Sales Service

10
10.1

Spare Parts and After Sales Service

Service Parts and Expendable Parts
Name Set of V---belts Air filter Nonreturn valve Solenoid valve Solenoid valve Oil filter Lubricating oil Strainer in the inlet line Sealing ---ring Strainer Sealing ---ring No. off 3 x SPA x 2882 1 off 1 off 1 off 1 off 1 off 1 litre 1 off 1 off 1 off 1 off Part number 6.2544.0 6.0175.0 8.0225.1 7.1360.0 7.1950.0 9.2147.00010 9.0894.0 8.0502.0 6.3494.0 8.0414.00020 6.1524.0

10.2

Ordering Spare Parts

When ordering spare parts always state (see nameplate): --- Compressor model --- Year of manufacture --- Part number --- Serial number

10 --- 45

Spare Parts and After Sales Service

Important for all queries:  Enter the data from the nameplate of the compressor unit in the nameplate illustrated above.

Always quote the data on the nameplate when ordering spare parts or making enquiries. Attention! Do not fit inferior consumable or spare parts. Use only original parts supplied by the compressor manufacturer.

We must point out that maintenance parts, spare parts and accessories not delivered by KAESER are also not tested and cleared by us. The fitting and/or use of such products can, under certain circumstances, change the design characteristics of the compressor unit negatively and therefore affect the active and/or passive safety of the unit. The use of such parts or accessories exempts KAESER from all liabilities and warranties for consequential damage caused by such parts or accessories.

10 --- 46

Appendix
11
11.1

Appendix
Maintenance Record
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date Description of work Operating hours Signature

11 --- 47