Table of Contents
Related Manuals for KAESER KOMPRESSOREN EPC 150-2-G
Summary of Contents for KAESER KOMPRESSOREN EPC 150-2-G
- Page 1 Assembly 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.com...
- Page 2 /KKW/PEPC 2.04 en SBA-KOLBEN-AGGREGAT 2-STUFIG 20170303 120300...
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Page 3: Table Of Contents
Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Specifications Nameplate ........................Options ..........................Mass ..........................Compressor block ...................... - Page 4 Contents 4.2.2 Silenced air filter ....................4.2.3 Air filter with plastic casing .................. 4.2.4 Castors ....................... 4.2.5 Screwable rubber pads for air receiver mounting ..........4.2.6 Screwable rubber pads ..................Operating modes and control modes ................4.3.1 Machine operating modes .................. 4.3.2 External control unit ....................
- Page 5 Contents Fault Recognition and Rectification Basic instructions ......................Faults ..........................Maintenance 10.1 Ensuring safety ........................ 10.2 Following the maintenance plan ..................10.2.1 Logging maintenance work ................. 10.2.2 Regular maintenance tasks ................10.2.3 Compressor oil Change interval ................. 10.2.4 Regular service tasks ..................10.3 Maintaining the air cooler or fan cowl ................
- Page 6 Contents Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E...
- Page 7 List of Illustrations Fig. 1 Location of safety signs ......................Fig. 2 Machine overview ........................Fig. 3 Option C5: Oil level monitoring ....................Fig. 4 Option H9: Silenced air filter ....................... Fig. 5 Option H10: Air filter with plastic casing ..................Fig.
- Page 8 List of Illustrations Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E...
- Page 9 List of Tables Tab. 1 Danger levels and their definition (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options ............................Tab. 5 Mass ............................Tab. 6 Compressor block ........................Tab.
- Page 10 List of Tables Assembly and operating manual 2-stage piston compressor viii EPC-2-G No.: 9_5753 24 E...
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Page 11: Regarding This Document Using This Document
Regarding this document Using this document 1 Regarding this document Using this document This document, hereafter called the service manual, contains important information about all life phases of the machine. The operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. -
Page 12: Potential Damage Warnings
Regarding this document Symbols and labels Example: DANGER These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur. - Page 13 Regarding this document Symbols and labels Material Here you will find details on special tools, operating materials or spare parts. Precondition Here you will find conditional requirements necessary to carry out the task. Here conditions relevant to safety are named that will help you to avoid dangerous situations. Option H1 ➤...
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Page 14: Technical Specifications Nameplate
Tab. 4 Options Mass The values shown are maximum values. The actual weight depends on equipment fitted. Compressor model Mass [kg] EPC 150-2-G 40/95 Machine with sound enclosure Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E... -
Page 15: Compressor Block
Tab. 5 Mass Compressor block Compressor block model Compressor model Number of cylinders Flow rate at 12 bar [l/min] KC 150-2 EPC 150-2-G KC 236-2 EPC 230-2-G KC 420-2 EPC 420-2-G KC 550-2 EPC 550-2-G KC 750-2 EPC 750-2-G KC 1000-2... -
Page 16: Pressure
Forced ventilation: Required air volume for exhaust fan at static compression 1 mbar (machine in enclosed space without ducts and ΔT≙10 K) Tab. 8 Ventilation Pressure Cylinder relief valve EPC 150-2-G / EPC 230-2-G EPC 420-2-G to EPC 1000-2-G Maximum working overpres‐ sure [bar] Pressure relief valve 17.5... -
Page 17: Motor Power And Speed
➤ Read off the enclosure protection class from the motor nameplate and enter in the table. Compressor model Rated pow‐ Rated speed Rated speed Enclosure pro‐ er [kW] tection [min ] (50 Hz) [min ] (60 Hz) EPC 150-2-G 1500 1800 EPC 230-2-G 1500 1800 EPC 420-2-G 1500 1800 EPC 550-2-G 1500 1800... -
Page 18: Compressor Oil Charge
Oil contained in my compressor Tab. 14 Compressor oil recommendation 2.10.1 Compressor oil charge Compressor model Total charge [litres] Topping up volume [l] (minimum–maximum) EPC 150-2-G 0.25 EPC 230-2-G 0.25 EPC 420-2-G 0.22 EPC 550-2-G 0.22 EPC 750-2-G 0.37 EPC 1000-2-G 0.37... -
Page 19: Tab. 16 Supply Details 230V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection The connection to an IT three-phase supply or a three-phase supply with one earthed phase is not permitted. Further information When connecting to a European 400V/3/50Hz rated voltage the requirements in chapter 2.12 are also to be observed. 2.11.1.1 Power supply specifications The following supply cable conductor cross sections and fusing (slow-blow class gG) are selected... -
Page 20: Tab. 17 Supply Details 400V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection Rated voltage: 400V / 3 / 50Hz Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 150-2-G ● 4 x 1.5 230-2-G ● 4 x 1.5 4 x 1.5 420-2-G... -
Page 21: Tab. 19 Supply Details 690V / 3 / 50Hz
Technical Specifications 2.11 Electrical connection Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 1000-2-G 10.4 ● 4 x 1.5 – – ● Pressure switch ○ controller (START CONTROL) Tab. -
Page 22: Electrical Connection Data For Oil Level Monitoring
Technical Specifications 2.11 Electrical connection Rated voltage: 440V±10% / 3 / 60Hz Current Direct start Star-delta start drawn [A] Backup Supply ca‐ Backup Supply ca‐ fuse [A] fuse [A] ble [mm ble [mm 150-2-G ● 4 x 1.5 – – 230-2-G ●... -
Page 23: Mains Conditions
If necessary, ask the local electricity utility for the mains conditions. 2.12.1 Supply conditions at 400V/3/50Hz Compressor model Start configuration Maximal permissible Highest permissible motor starts [1/h] System impedance [Ω] max. EPC 150-2-G Direct online 0.767 EPC 230-2-G 0.360 EPC 420-2-G 0.099 EPC 550-2-G 0.077 EPC 750-2-G Star-delta 0.178 EPC 1000-2-G 0.104... -
Page 24: Tab. 26 Machine Duty Cycle
■ Ambient temperature 20 °C ■ 30 % relative humidity ■ 1013 mbar air pressure Compressor model 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 ≤... -
Page 25: Safety And Responsibility Basic Instructions
Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■... -
Page 26: User's Responsibilities
Safety and Responsibility User's responsibilities ➤ Do not allow the machine to take in toxic, acidic, flammable or explosive gases or vapours. ➤ Do not operate the machine in areas in which specific requirements with regard to explosion protection are in force. User's responsibilities 3.4.1 Observe statutory and universally accepted regulations... -
Page 27: Dangers
Safety and Responsibility Dangers Examples of German operation DGUV Regel 100 – 500 , chapter 2.11: ➤ Carry out recurring inspections to The user must ensure that from a rated motor power greater than 0.5 kW the machine's safety devices are checked for function at least once annually. Dangers Basic instructions Information concerning the various forms of danger that can arise during heat exchanger operation... - Page 28 Safety and Responsibility Dangers Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐ clude health and life-threatening dangers. ➤ Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and/or for the processing of foodstuffs.
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Page 29: Safe Machine Operation
Safety and Responsibility Dangers ➤ Do not inhale oil mist and vapours. ➤ Do not eat or drink while handling cooling and lubricating fluids. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine. - Page 30 Safety and Responsibility Dangers ➤ Use suitable lifting gear that conforms to local safety regulations. ➤ Allow transportation only by personnel trained in the safe movement of loads. ➤ Attach lifting gear only to suitable lifting points. ➤ Be aware of the centre of gravity to avoid tipping. ➤...
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Page 31: Organisational Measures
Safety and Responsibility Dangers ➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no voltage is present. ➤ Check that there is no voltage on potential-free contacts. ➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐ sure that no compressed air can flow back into the machine. -
Page 32: Safety Devices
Safety and Responsibility Safety devices Activity Danger area Authorised personnel Operation Within a 1 m radius of the machine. Operating personnel Maintenance Within the machine. Maintenance personnel Within a 1 m radius of the machine. Tab. 27 Danger Areas Safety devices Various safety devices ensure safe working with the machine. -
Page 33: Information Signs
Safety and Responsibility Information signs Item Sign Meaning Hot surface! Risk of burns caused by contact with hot components ➤ Do not touch the surface. ➤ Wear long-sleeved garments (not synthetics such as polyester) and protective gloves. Tab. 28 Safety Signs Information signs The table lists the various information signs used and their meanings. -
Page 34: Injury From Handling Compressor Oil
Safety and Responsibility 3.11 Warranty Extinguishing substances ➤ Suitable extinguishing media: Foam Carbon dioxide Sand or soil ➤ Unsuitable extinguishing media: Strong jet of water 3.10.2 Injury from handling compressor oil Eye contact: Compressor oil can cause irritation. ➤ Rinse open eyes thoroughly for a few minutes under running water. ➤... -
Page 35: Environment Protection
Safety and Responsibility 3.12 Environment protection Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.12 Environment protection The operation of this machine may cause dangers for the environment. ➤... -
Page 36: Design And Function
Design and Function Outline of the machine 4 Design and Function Outline of the machine 4.1.1 Machine structure Fig. 2 Machine overview Air filter Air pipe* Compressor block Air cooler* Compressor motor Fan with cowl* Oil filler port Cylinder or collecting pipe Oil sight glass relief valve* Oil drain plug... -
Page 37: Options
Design and Function Options The compressed air passes through the cooling pipe or cooler to the compressed air outlet. Options The options available for your machine are described below. 4.2.1 Option C5 Oil level monitoring The oil level in the machine is monitored automatically. The machine is automatically shut down if the oil level falls below minimum. -
Page 38: Castors
Design and Function Options Fig. 5 Option H10: Air filter with plastic casing Air filter cartridge 4.2.4 Option H14 Castors For moving the machine easily. Only in combination with a sound enclosure. Fig. 6 Option H14: Castors Castors Wheel stops 4.2.5 Option H20 Screwable rubber pads for air receiver mounting... -
Page 39: Screwable Rubber Pads
Design and Function Operating modes and control modes 4.2.6 Option H29 Screwable rubber pads These rubber pads allow the machine to be anchored firmly to the floor. Fig. 8 Option H29: Screwable rubber pads Screwable rubber pad Threaded connection Operating modes and control modes 4.3.1 Machine operating modes There are two operating modes:... -
Page 40: Safety Devices
Design and Function Safety devices Safety devices The following safety devices are provided and may not be modified in any way. ■ Pressure relief valve: The pressure relief valve protects the system against excessive pressure. It is factory set. ■ Housing and covers for moving parts and electrical connections: Protect against accidental contact. -
Page 41: Accessories
Design and Function Accessories Accessories To reduce the machine's noise emission, it can be retrospectively fitted with a sound enclosure. Further information Instructions on installation of a sound enclosure can be found in chapter 6.10. Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G... -
Page 42: Installation And Operating Conditions
Installation and Operating Conditions Ensuring safety 5 Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 43: Ensuring The Machine Room Ventilation
Installation and Operating Conditions Installation conditions Fig. 9 Recommended machine placement and dimensions [mm] Exhaust fan Air inlet aperture NOTICE! Ambient temperature too low. The reduced lubrication properties of oil that is too viscous can result in damage when starting the machine. -
Page 44: Prevention Of Thermal Problems
Installation and Operating Conditions Installation conditions 3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely through the room. 4. Ensure clean air in order to support the proper functioning of the machine. Further information See chapter 2.6 for ventilation aperture dimensions. -
Page 45: Installation
Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 46: Reporting Transport Damage
Installation Reporting Transport Damage Reporting Transport Damage 1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. Fitting the rubber pads CAUTION There is a danger of tilting because of the high centre of gravity and mass of the machine. ➤... -
Page 47: Connecting The Machine With The Compressed Air Network
Installation Connecting the machine with the compressed air network Connecting the machine with the compressed air network Condensate in the compressed air network can damage the pipework: ➤ Install only corrosion-resistant pipes. ➤ Use fluoroelastomers as sealing material for seals. ➤... -
Page 48: Installation Examples
Installation Installation examples Fig. 13 Install the venting valve on-site Venting valve on the pressure switch Venting valve (solenoid valve) at the compressed air discharge point 1. DANGER! Dangerous voltage! There is danger of fatal injury caused by contact with live components. ➤... -
Page 49: Fig. 14 Typical Installation Of Safety And Regulating Devices
Installation Installation examples Fig. 14 Typical installation of safety and regulating devices Air receiver Pressure gauge Pressure switch Shut-off valve compressed air outlet Check valve Shut-off valve compressed air inlet Flexible pressurised hose to the machine Shut-off valve condensate drain Pressure relief valve Nozzle (machine-dependent) Test flange... -
Page 50: Two Machines With One Air Receiver
Installation Connecting the machine to the power supply 6.7.2 Two machines with one air receiver Fig. 15 Typical installation of two machines with one air receiver Air receiver Test flange Pressure switch Pressure gauge Check valve Shut-off valve compressed air outlet Machine Shut-off valve compressed air inlet Flexible pressurised hose to the machine... -
Page 51: Options
Installation Options 2. Carry out safety measures as stipulated in relevant regulations (e.g. IEC 364 or DIN VDE 0100) and in applicable national accident prevention regulations (BGV A3 in Germa‐ ny). In addition, observe the regulations of the local electricity supplier. 3. -
Page 52: Fig. 16 Option C5: Oil Level Monitoring
Installation Options Fig. 16 Option C5: Oil level monitoring Compressor block Oil level monitoring The contact in the oil level monitor is wired at the factory as a normally open contact. Oil level Electrical contact rises closes falls opens Tab. 30 Option C5: Oil level monitoring factory setting ➤... -
Page 53: Fig. 17 Option C5: Changing The Oil Level Monitoring Setting
Installation Options Adjusting the setting Adjust the switching point by moving the sensing contact slightly along an arrow. You may fine-adjust the switching point to the length of the arrow. ■ Moving towards the arrow head lowers the oil level point at which the sensor triggers. ■... -
Page 54: Mounting The Machine On An Air Receiver
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.9.2 Option H20 Mounting the machine on an air receiver Fig. 18 Option H20: Screwable rubber pads Screwable rubber pad Threaded connection Model A Hexagon bolt Model B Hexagonal nut ➤ Use appropriate fixing elements to anchor the machine. Further information Details of the anchoring threads are shown in the dimensional drawing in chapter 13.2. -
Page 55: Dismantling The Sound Enclosure
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.10.1 Dismantling the sound enclosure Note how the parts fit together. ➤ Open the snap fastener and unscrew the enclosure from the base plate. 6.10.2 Fitting the sound enclosure Prior to any work requiring the opening of the pressure system, the machine must be fully iso‐ lated from the compressed air network and completely depressurised. -
Page 56: Fig. 20 Modifying The Air Filter, Epc 150-2-G / Epc 230-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Replacing the compressor block's base plate and modifying the air filter Fig. 20 Modifying the air filter, EPC 150–2–G / EPC 230–2–G Base plate, compressor block Before modification Air filter After modification Angle 1. -
Page 57: Fig. 21 Installing The Sound Enclosure, Epc 150-2-G / Epc 230-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 21 Installing the sound enclosure, EPC 150–2–G / EPC 230–2–G Rubber pad Fan with cowl Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Rubber pad Sound enclosure Base plate Air inlet louver Compressor block Removable panel... -
Page 58: Fig. 22 Modifying The Air Filter, Epc 420-2-G / Epc 550-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) 6.10.2.2 EPC 420–2–G / EPC 550–2–G Material Supplied additional components for air filter Modifying the air filter Fig. 22 Modifying the air filter, EPC 420–2–G / EPC 550–2–G Air filter Before modification Angle After modification 1. -
Page 59: Fig. 23 Installing The Sound Enclosure, Epc 420-2-G / Epc 550-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 23 Installing the sound enclosure, EPC 420-2–G / EPC 550-2–G Rubber pad Sheet metal collar Rubber pad Compressed air cooler Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Spacer Sound enclosure Base plate Air inlet louver... -
Page 60: Fig. 24 Modifying The Air Filter, Epc 750-2-G / Epc 1000-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) 8. Attach the sound enclosure to the base plate. 9. Screw the inlet air inlet louvre to the enclosure, hang the panel (exhaust louvre) in the enclo‐ sure and secure it with the snap fasteners. 6.10.2.3 EPC 750–2–G / EPC 1000–2–G Material... -
Page 61: Fig. 25 Installing The Sound Enclosure, Epc 750-2-G / Epc 1000-2-G
Installation 6.10 Retrofitting the sound enclosure (accessory) Fig. 25 Installing the sound enclosure, EPC 750-2–G / EPC 1000-2–G Rubber pad Sheet metal collar Rubber pad Compressed air cooler Rubber pad Pre-cut foam Z-profile User's check valve Bracket Hose line Spacer Sound enclosure Base plate Air inlet louver... - Page 62 Installation 6.10 Retrofitting the sound enclosure (accessory) 8. Attach the sound enclosure to the base plate. 9. Screw the inlet air inlet louvre to the enclosure, hang the panel (exhaust louvre) in the enclo‐ sure and secure it with the snap fasteners. Assembly and operating manual 2-stage piston compressor EPC-2-G...
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Page 63: Initial Start-Up Ensuring Safety
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 64: Instructions To Be Observed Before Commissioning Or Re-Commissioning
Initial Start-up Instructions to be observed before commissioning or re-commissioning Instructions to be observed before commissioning or re-commis‐ sioning Incorrect or improper commissioning can cause injury to persons and damage to the machine. ➤ Commissioning may only be carried out by authorized installation and service personnel who have been trained on this machine. -
Page 65: Motor Protection
Initial Start-up Motor protection To be checked See chapter Confirmed? ➤ Oil level monitor connected? 6.9.1 ➤ Is the machine firmly anchored to the floor? 6.9.3 ➤ Are all access doors closed and latched and all removable panels in – place and secured? (Sound enclosure) depending on machine Tab. -
Page 66: Checking The Direction Of Rotation
Initial Start-up Checking the direction of rotation Checking the direction of rotation The machine is designed for three-phase connection with right phase rotation. Ideally, the direction of phase rotation should be measured with a phase sequence meter. Alterna‐ tively, start the machine very briefly and observe the direction of rotation of the motor cooling fan. 1. -
Page 67: Operation
Operation Switching on and off 8 Operation Switching on and off Always switch the machine on and off with the «ON/OFF» switch. Depending on the starter type, the «ON/OFF» switch may be found on the user's pressure switch or on the external controller. The following starting modes are available: ■... -
Page 68: Direct Online Start With Solenoid Valve
Operation Switching on and off Result The machine starts as soon as network pressure is lower than the cut-out pressure. Switching off 1. Switch off the compressor at the user's pressure switch. 2. Switch off and lock out the power supply isolating device. 8.1.2 Direct online start with solenoid valve Precondition... - Page 69 Operation Switching on and off Switching off 1. Switch off the machine via the external controller. 2. Switch off and lock out the power supply isolating device. Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G...
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Page 70: Fault Recognition And Rectification
Fault Recognition and Rectification Basic instructions 9 Fault Recognition and Rectification Basic instructions The alarm indications valid for your machine are dependent on the individual equipment. 1. Do not attempt fault rectification measures other than those given in this manual! 2. - Page 71 Fault Recognition and Rectification Faults Fault Possible cause Remedy Machine runs hot. Ambient temperature too high. Reduce the ambient tempera‐ ture. Wrong direction of rotation. Changeover phase lines L1 and Fan cannot draw air freely. Ensure unrestricted flow of air to the fan.
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Page 72: Tab. 34 Faults And Remedies
Fault Recognition and Rectification Faults Fault Possible cause Remedy Air leaks from the user's pres‐ Defective switch diaphragm. Call KAESER SERVICE. sure switch while the machine The venting valve is not clos‐ Maintain or replace the unload‐ is running. ing. ing valve. -
Page 73: 10.1 Maintenance
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤... -
Page 74: Following The Maintenance Plan
Maintenance 10.2 Following the maintenance plan 10.2 Following the maintenance plan 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■... -
Page 75: Regular Service Tasks
Maintenance 10.3 Maintaining the air cooler or fan cowl Advice can be obtained from KAESER SERVICE on determining suitable changing intervals. ➤ Check operating conditions and adjust intervals as necessary; log the results in table 36 for fu‐ ture reference. Maximum permissible oil change interval [operating hours/years] Compressor oil... -
Page 76: Cleaning The Air Cooler Or Fan Cowl
Maintenance 10.4 Air filter maintenance Material Brush Vacuum cleaner As required: Respiratory protection Precondition The supply disconnecting device is switched off, the device is locked off, a check has been made that no voltage is present. The machine has cooled down. Fig. -
Page 77: Air Filter (Sound Damping) Maintenance
Maintenance 10.5 Air filter (sound damping) maintenance Fig. 28 Air filter maintenance Air filter Retaining clip Inlet air opening Cover Filter element 1. Unscrew the air filter from the cylinder head. 2. Release the retaining clip and take off the cover. 3. -
Page 78: Air Filter (Plastic Housing) Maintenance
Maintenance 10.6 Air filter (plastic housing) maintenance Cleaning the filter element with compressed air 1. Release the retaining clip and take off the cover. 2. Withdraw the filter element. 3. Use dry compressed air (<5 bar!) to blow dirt from the air filter cartridge at a slant from the in‐ side to the outside. -
Page 79: Drive Motor Maintenance
Maintenance 10.7 Drive motor maintenance 4. Inspect the air filter element for any damage. Change the air filter element if damaged. 5. Clean the housing and sealing faces. 6. Replace the filter element. 7. Replace the cover and screw down tight. 8. -
Page 80: Changing The Compressor Oil
Maintenance 10.10 Changing the compressor oil CAUTION The machine can be damaged by unsuitable oil. ➤ Never mix different types of oil. ➤ Never top up with a different type of oil to that already used in the machine. The type of compressor oil used is listed in table 14. Fig. -
Page 81: Check The Pressure Relief Valve
Maintenance 10.11 Check the pressure relief valve Fig. 33 Changing the compressor oil Oil filler port Oil sight glass Oil drain plug Draining the oil 1. Remove the crankcase vent from the oil filler. 2. Prepare a oil receptacle. 3. Remove the drain plug and allow oil to drain into the receptacle. 4. -
Page 82: Venting The Machine (De-Pressurising)
Maintenance 10.12 Venting the machine (de-pressurising) The valve opens to protect the machine if the maximum permissible working pressure is ex‐ ceeded. ➤ Never operate the machine without a correctly functioning pressure relief valve. ➤ Do not adjust the pressure relief valve. Precondition Machine runs in LOAD Fig. -
Page 83: Solenoid Valve Maintenance
Maintenance 10.13 Solenoid valve maintenance 1. DANGER! Compressed air! ➤ Compressed air and devices under pressure can injure or cause death if the contained en‐ ergy is released suddenly. ➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to ensure that no compressed air can flow back into the machine. -
Page 84: Cleaning The Solenoid Valve
Maintenance 10.13 Solenoid valve maintenance 10.13.1 Cleaning the solenoid valve Fig. 35 Cleaning the solenoid valve Solenoid valve Piston Screw Housing Coil Connecting socket Armature Arrow showing flow direction Spring 1. Remove the connecting socket from the solenoid valve. 2. Undo the screw and carefully remove the coil. 3. -
Page 85: Replacing The Solenoid Valve
Maintenance 10.14 Cylinder head and valves 10.13.2 Replacing the solenoid valve Fig. 36 Replacing the solenoid valve Solenoid valve Damper Screw connection Connecting socket 1. Remove the connecting socket from the solenoid valve. 2. Unscrew the defective solenoid valve wit damper from double nipple. 3. -
Page 86: Cleaning The Cylinder Head And Valves
Maintenance 10.14 Cylinder head and valves 10.14.2 Cleaning the cylinder head and valves The machine must be isolated from the compressed air network and completely vented before un‐ dertaking any work on the air main. Precondition The power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified. -
Page 87: Documenting Maintenance And Service Work
Maintenance 10.15 Documenting maintenance and service work 10.15 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 39 Logged maintenance tasks Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G... -
Page 88: 11 Spares, Operating Materials, Service
Spares, Operating Materials, Service 11.1 Note the nameplate 11 Spares, Operating Materials, Service 11.1 Note the nameplate The nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤... -
Page 89: Kaeser Air Service
Spares, Operating Materials, Service 11.3 KAESER AIR SERVICE 11.3 KAESER AIR SERVICE KAESER AIR SERVICE offers: ■ Authorised service technicians with KAESER factory training ■ Increased operational reliability ensured by preventive maintenance ■ Energy savings achieved by avoidance of pressure losses ■... -
Page 90: 12.1 Decommissioning, Storage And Transport
Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: ■ The machine is (temporarily) not needed. ■ The machine is to be moved to another location. ■ The machine is to be scrapped. -
Page 91: Storage
Decommissioning, Storage and Transport 12.3 Storage 12.3 Storage Moisture can lead to corrosion, particularly on the surfaces of the compressor block. Frozen moisture can damage components, valve diaphragms and gaskets. Please consult with KAESER if you have questions to the appropriate storage and commis‐ sioning. -
Page 92: Disposal
Decommissioning, Storage and Transport 12.5 Disposal ➤ Please consult with KAESER if you have questions to the appropriate lifting gear. Precondition The lifting gear complies with local safety regulations. Fig. 39 Transporting with a crane 1. CAUTION! The machine can be damaged by incorrect attachment of the lifting gear! ➤... -
Page 93: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G... - Page 94 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E...
- Page 95 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G...
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Page 96: Dimensional Drawing
Annex 13.2 Dimensional Drawing 13.2 Dimensional Drawing Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E... - Page 97 Annex 13.2 Dimensional Drawing Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G...
- Page 98 Annex 13.2 Dimensional Drawing Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E...
- Page 99 Annex 13.2 Dimensional Drawing Assembly and operating manual 2-stage piston compressor No.: 9_5753 24 E EPC-2-G...
- Page 100 Annex 13.2 Dimensional Drawing Assembly and operating manual 2-stage piston compressor EPC-2-G No.: 9_5753 24 E...