KAESER KOMPRESSOREN EPC 1000-2-G Manuals

Manuals and User Guides for KAESER KOMPRESSOREN EPC 1000-2-G. We have 2 KAESER KOMPRESSOREN EPC 1000-2-G manuals available for free PDF download: Assembly And Operating Manual

KAESER KOMPRESSOREN EPC 1000-2-G Assembly And Operating Manual (100 pages)

2-stage piston compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 5.52 MB

Table of Contents
3
Regarding this Document Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definition (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
Technical Specifications Nameplate
14
Options
14
Mass
14
Tab. 3 Nameplate
14
Tab. 4 Options
14
Compressor Block
15
Ambient Conditions
15
Ventilation
15
Tab. 5 Mass
15
Tab. 6 Compressor Block
15
Tab. 7 Ambient Conditions
15
Pressure
16
Noise Emission [Db(A)]
16
Tab. 8 Ventilation
16
Tab. 9 Cylinder Relief Valve - Pressure Data
16
Tab. 10 Pressure Indication for Pressure Relief Valve at Air Cooler
16
Motor Power and Speed
17
Compressor Oil Recommendation
17
Tab. 11 Noise Emission [Db(A)]
17
Tab. 12 Motor Power and Speed
17
Tab. 13 Permissible Starting Frequency
17
Compressor Oil Charge
18
Electrical Connection
18
Three-Phase Power Supply
18
Tab. 14 Compressor Oil Recommendation
18
Tab. 15 Compressor Oil Charge
18
Tab. 16 Supply Details 230V / 3 / 50Hz
19
Tab. 17 Supply Details 400V / 3 / 50Hz
20
Tab. 18 Supply Details 500V / 3 / 50Hz
20
Tab. 19 Supply Details 690V / 3 / 50Hz
21
Tab. 20 Supply Details 230V / 3 / 60Hz
21
Tab. 21 Supply Details 380V / 3 / 60Hz
21
Electrical Connection Data for Oil Level Monitoring
22
Tab. 22 Supply Details 440V / 3 / 60Hz
22
Tab. 23 Supply Details 460V / 3 / 60Hz
22
Tab. 24 Option C5: Connection Data for Oil Level Monitoring
22
Mains Conditions
23
Supply Conditions at 400V/3/50Hz
23
Machine Duty Cycle
23
Tab. 25 Network Impedance
23
Tab. 26 Machine Duty Cycle
24
Safety and Responsibility Basic Instructions
25
Specified Use
25
Improper Use
25
User's Responsibilities
26
Observe Statutory and Universally Accepted Regulations
26
Determining Personnel
26
Keeping to Inspection Schedules and Accident Prevention Regulations
26
Dangers
27
Safely Dealing with Sources of Danger
27
Safe Machine Operation
29
Organisational Measures
31
Danger Areas
31
Safety Devices
32
Safety Signs
32
Fig. 1 Location of Safety Signs
32
Tab. 27 Danger Areas
32
Information Signs
33
In Emergency
33
Correct Fire Fighting
33
Tab. 28 Safety Signs
33
Tab. 29 Information Signs
33
Injury from Handling Compressor Oil
34
Warranty
34
Environment Protection
35
Design and Function
36
Outline of the Machine
36
Machine Structure
36
Machine Function
36
Fig. 2 Machine Overview
36
Options
37
Oil Level Monitoring
37
Silenced Air Filter
37
Air Filter with Plastic Casing
37
Fig. 3 Option C5: Oil Level Monitoring
37
Fig. 4 Option H9: Silenced Air Filter
37
Castors
38
Screwable Rubber Pads for Air Receiver Mounting
38
Fig. 5 Option H10: Air Filter with Plastic Casing
38
Fig. 6 Option H14: Castors
38
Fig. 7 Option H20: Screwable Rubber Pads
38
Screwable Rubber Pads
39
Operating Modes and Control Modes
39
Machine Operating Modes
39
External Control Unit
39
Fig. 8 Option H29: Screwable Rubber Pads
39
Safety Devices
40
Safety and Regulating Devices
40
Accessories
41
Installation and Operating Conditions
42
Ensuring Safety
42
Installation Conditions
42
Determining Location and Clearances
42
Ensuring the Machine Room Ventilation
43
Fig. 9 Recommended Machine Placement and Dimensions [MM]
43
Prevention of Thermal Problems
44
Operating the Machine in a Compressed Air Network
44
Installation
45
Ensuring Safety
45
Reporting Transport Damage
46
Fitting the Rubber Pads
46
Replacing the Air Filter
46
Fig. 10 Fitting the Rubber Pads
46
Fig. 11 Replacing the Air Filter
46
Connecting the Machine with the Compressed Air Network
47
Installing the Venting Valve
47
Fig. 12 Compressed Pipework
47
Installation Examples
48
Safety and Control Devices
48
Fig. 13 Install the Venting Valve On-Site
48
Fig. 14 Typical Installation of Safety and Regulating Devices
49
Two Machines with One Air Receiver
50
Connecting the Machine to the Power Supply
50
Fig. 15 Typical Installation of Two Machines with One Air Receiver
50
Options
51
Oil Level Monitoring
51
Fig. 16 Option C5: Oil Level Monitoring
52
Tab. 30 Option C5: Oil Level Monitoring Factory Setting
52
Fig. 17 Option C5: Changing the Oil Level Monitoring Setting
53
Mounting the Machine on an Air Receiver
54
Anchoring the Machine
54
Retrofitting the Sound Enclosure (Accessory)
54
Fig. 18 Option H20: Screwable Rubber Pads
54
Fig. 19 Option H29: Securing the Screwable Rubber Pads
54
Dismantling the Sound Enclosure
55
Fitting the Sound Enclosure
55
Fig. 20 Modifying the Air Filter, EPC 150-2-G / EPC 230-2-G
56
Fig. 21 Installing the Sound Enclosure, EPC 150-2-G / EPC 230-2-G
57
Fig. 22 Modifying the Air Filter, EPC 420-2-G / EPC 550-2-G
58
Fig. 23 Installing the Sound Enclosure, EPC 420-2-G / EPC 550-2-G
59
Fig. 24 Modifying the Air Filter, EPC 750-2-G / EPC 1000-2-G
60
Fig. 25 Installing the Sound Enclosure, EPC 750-2-G / EPC 1000-2-G
61
Initial Start-Up Ensuring Safety
63
Instructions to be Observed before Commissioning or Re-Commissioning
64
Checking Installation and Operating Conditions
64
Tab. 31 Re-Commissioning after Storage
64
Motor Protection
65
Motor Protection Setting by Direct Online Starting
65
Motor Protection Setting by Star-Delta Starting
65
Tab. 32 Check List of Installation Conditions
65
Checking the Direction of Rotation
66
Starting the Machine for the First Time
66
Measuring the Air Receiver Filling Time
66
Tab. 33 Air Receiver Filling Time
66
Operation
67
Switching on and off
67
Direct Start
67
Fig. 26 Switching the Compressed Air Station on and off
67
Direct Online Start with Solenoid Valve
68
Star-Delta Start
68
Fault Recognition and Rectification
70
Basic Instructions
70
Faults
70
Tab. 34 Faults and Remedies
72
10.1 Maintenance
73
Ensuring Safety
73
Following the Maintenance Plan
74
Logging Maintenance Work
74
Regular Maintenance Tasks
74
Compressor Oil Change Interval
74
Tab. 35 Regular Maintenance Tasks
74
Regular Service Tasks
75
Maintaining the Air Cooler or Fan Cowl
75
Tab. 36 Compressor Oil Change Intervals
75
Tab. 37 Regular Service Tasks
75
Cleaning the Air Cooler or Fan Cowl
76
Air Filter Maintenance
76
Fig. 27 Cleaning the Air Cooler or Fan Cowl
76
Air Filter (Sound Damping) Maintenance
77
Fig. 28 Air Filter Maintenance
77
Fig. 29 Option H9: Air Filter (Sound Damping) Maintenance
77
Air Filter (Plastic Housing) Maintenance
78
Fig. 30 Option H10: Air Filter (Plastic Housing) Maintenance
78
Drive Motor Maintenance
79
Checking the Oil Level
79
Topping up the Compressor Oil
79
Fig. 31 Checking the Oil Level
79
Changing the Compressor Oil
80
Fig. 32 Topping up the Compressor Oil
80
Check the Pressure Relief Valve
81
Pressure Relief Valves on the Cylinder Head, Collecting Pipe and Air Cooler
81
Fig. 33 Changing the Compressor Oil
81
Venting the Machine (De-Pressurising)
82
Fig. 34 Checking the Pressure Relief Valves on the Cylinder Head, Collecting Pipe and Air Cooler
82
Solenoid Valve Maintenance
83
Cleaning the Solenoid Valve
84
Fig. 35 Cleaning the Solenoid Valve
84
Replacing the Solenoid Valve
85
Cylinder Head and Valves
85
Checking Cylinder Head and Valves
85
Fig. 36 Replacing the Solenoid Valve
85
Cleaning the Cylinder Head and Valves
86
Starting the Machine and Performing a Trial Run
86
Tab. 38 Tightening Torque for Cylinder Head Screws
86
Documenting Maintenance and Service Work
87
Tab. 39 Logged Maintenance Tasks
87
11 Spares, Operating Materials, Service
88
Note the Nameplate
88
Ordering Consumable Parts and Operating Fluids/Materials
88
Fig. 37 Consumable Parts
88
Tab. 40 Consumable Parts
88
Kaeser Air Service
89
Replacement Parts for Service and Repair
89
12.1 Decommissioning, Storage and Transport
90
Commissioning
90
Packing
90
Storage
91
Transport
91
Safety
91
Transport with a Forklift Truck
91
Transport with a Crane
91
Fig. 38 Transporting with a Forklift Truck
91
Disposal
92
Fig. 39 Transporting with a Crane
92
13 Annex
93
Pipeline and Instrument Flow Diagram (P&I Diagram)
93
Dimensional Drawing
96

KAESER KOMPRESSOREN EPC 1000-2-G Assembly And Operating Manual (96 pages)

2-stage piston compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 2.08 MB

Table of Contents
3
Regarding this Document Using this Document
11
Further Documents
11
Copyright
11
Symbols and Markings
11
Warning Notices
11
Other Notices and Symbols
12
Tab. 1 the Levels of Danger and Their Meaning
12
Technical Specification Nameplate
13
Options
13
Weight
13
Tab. 2 Nameplate
13
Tab. 3 Options
13
Compressor Block
14
Ambient Conditions
14
Ventilation
14
Tab. 4 Weight
14
Tab. 5 Compressor Block Specification
14
Tab. 6 Ambient Conditions
14
Pressure
15
Sound Pressure Level
15
Tab. 7 Ventilation
15
Tab. 8 Activating Pressure of the Cylinder Relief Valve EPC 150-2 und EPC 230-2
15
Tab. 9 Activating Pressure of the Cylinder Relief Valve EPC 420-2 bis EPC 1000-2
15
Tab. 10 Activating Pressure of the Air Cooler Relief Valve EPC 420-2 bis EPC 1000-2
15
Tab. 11 Sound Pressure Level
15
Motor Power and Speed
16
Compressor Oil Recommendations
16
Tab. 12 Power and Speed
16
Tab. 13 Permissible Starting Frequency
16
Compressor Oil Charge
17
Power Supply
17
Tab. 14 Compressor Oil Recommendations
17
Tab. 15 Compressor Oil Charge
17
Three-Phase Power Supply
18
Tab. 16 Supply Details 230V/3/50Hz
18
Tab. 17 Supply Details 400V/3/50Hz
19
Tab. 18 Supply Details 500V/3/50Hz
19
Tab. 19 Supply Details 690V/3/50Hz
20
Tab. 20 Supply Details 230V/3/60Hz
20
Tab. 21 Supply Details 380V/3/60Hz
20
Electrical Connection Details for Oil Level Monitoring
21
Tab. 22 Supply Details 440V/3/60Hz
21
Tab. 23 Supply Details 460V/3/60Hz
21
Tab. 24 Connection Details for Oil Level Monitoring
21
Network Conditions
22
Mains Conditions at 400V/3/50Hz
22
Machine Duty Cycle
22
Tab. 25 Network Impedance
22
Tab. 26 Machine Duty Cycle
23
Safety and Responsibility Basic Information
24
Specified Use
24
Improper Use
24
User's Responsibilities
24
Observe Statutory and Universally Accepted Regulations
24
Defining Personnel
25
Inspection Schedules and Accident Prevention Regulations
25
Tab. 27 Inspection Intervals According to Ordinance on Industrial Safety and Health
25
Dangers
26
Safely Dealing with Sources of Danger
26
Safe Machine Operation
28
Organisational Measures
28
Danger Areas
29
Safety Devices
29
Safety Signs
29
Tab. 28 Danger Areas
29
Information Signs
30
Fig. 1 Location of Safety Signs
30
Tab. 29 Safety Signs
30
Tab. 30 Information Signs
30
Emergency Situations
31
Correct Fire Fighting
31
Remove any Compressor Oil from Your Person
31
Warranty
31
Environmental Protection
32
Design and Function
33
Outline of the Machine
33
Main Components
33
Function
33
Fig. 2 List of Main Components
33
Fig. 3 Machine Layout
33
Options
34
Oil Level Monitoring
34
Adjustable Machine Mountings
34
Fig. 4 Oil Level Monitoring
34
Silenced Air Filter
35
Air Filter with Plastic Casing
35
Fig. 5 Adjustable Machine Mountings
35
Fig. 6 Silenced Air Filter
35
Castors
36
Bolt-On Machine Mounts for Mounting on Tank
36
Fig. 7 Air Filter with Plastic Casing
36
Fig. 8 Castors
36
Operating Modes and Control Modes
37
Operating Modes
37
External Control Unit
37
Safety Devices
37
Fig. 9 Bolt-On Machine Foot
37
Safety and Regulating Devices
38
Accessories
38
Installation and Operating Conditions
39
Safety
39
Installation Conditions
39
Determining Location and Clearances
39
Ensuring Adequate Ventilation
40
Fig. 10 Recommended Machine Placement and Dimensions [MM]
40
Operation in a Compressed Air Network
41
Installation Safety
42
Reporting Transport Damage
42
Fitting the Antivibration Mounts
42
Compressed Air Connection
43
Typical Installation for Safety and Regulating Devices
43
Fig. 11 Fitting the Antivibration Mounts
43
Fig. 12 Compressed Air Connection
43
Connecting the Power Supply
44
Fig. 13 Suggested Safety and Control Devices
44
Options
45
Oil Level Monitoring
45
Tab. 31 Oil Level Monitor
45
Fig. 14 Oil Level Monitor Connections
46
Fig. 15 Changing the Oil Level Monitoring Setting
47
Anchoring the Machine
48
Mounting the Machine on a Compressed Air Tank
48
Fig. 16 Securing the Bolt-On Machine Mounts
48
Fig. 17 Securing the Bolt-On Machine Mounts
48
Retrofitting the Sound Enclosure (Accessory)
49
Dismantling the Sound Enclosure
49
Vent the Machine (Depressurize)
49
Fig. 18 Removing the Air Filter
49
Fitting the Sound Enclosure
50
Fig. 19 Fitting the Sound Enclosure
50
Initial Start-Up Safety
51
Instructions to be Observed before Commissioning or Recommissioning
51
Checking Installation and Operating Conditions
52
Tab. 32 Re-Commissioning after Storage
52
Tab. 33 Checklist of Installation Conditions
52
Motor Overload Protection
53
Checking the Motor Protection Device
53
Checking Direction of Rotation
53
Starting the Machine for the First Time
53
Measuring the Air Receiver Filling Time
54
Tab. 34 Air Receiver Charging Time
54
Operation
55
Switching on and off
55
Direct Online Starting
55
Fig. 20 Switching on and off
55
Direct Online Start with Solenoid Valve
56
Star-Delta Starting
56
Fault Recognition and Rectification
58
Basic Information
58
Alarms
58
Tab. 35 Faults and Remedies
59
10.1 Maintenance
60
Safety
60
Maintenance Schedule
60
Logging Maintenance Work
60
Regular Maintenance Tasks
61
Oil Change Interval
61
Regular Service Tasks
61
Tab. 36 Regular Maintenance Tasks
61
Tab. 37 Oil Change Intervals
61
Maintaining the Air Cooler or Fan Guard
62
Fig. 21 Cleaning the Air Cooler or Fan Guard
62
Tab. 38 Regular Service Tasks
62
Cleaning the Air Cooler or Fan Guard
63
Air Filter Maintenance
63
Fig. 22 Air Filter Maintenance
63
Air Filter (Noise Absorbing) Maintenance
64
Fig. 23 Air Filter (Noise Absorbing) Maintenance
64
Air Filter (with Plastic Casing)
65
Fig. 24 Air Filter (with Plastic Casing)
65
Drive Motor Maintenance
66
Checking the Oil Level
66
Fig. 25 Checking the Oil Level
66
Topping up the Compressor Oil
67
Changing the Compressor Oil
67
Testing the Pressure Relief Valve
68
Pressure Relief Valves on the Cylinder Head, Collecting Pipe and Air Cooler
68
Fig. 26 Changing the Compressor Oil
68
Venting the Machine (De-Pressurising)
69
Fig. 27 Checking the Pressure Relief Valves on the Cylinder Head, Collecting Pipe and Air Cooler
69
Solenoid Valve Maintenance
70
Clean the Solenoid Valve
70
Fig. 28 Cleaning the Solenoid Valve
70
Changing the Solenoid Valve
71
Cylinder Head and Valves
71
Checking the Cylinder Head and Valves
71
Fig. 29 Changing the Solenoid Valve
71
Cleaning the Cylinder Head and Valves
72
Starting the Machine and Carrying out a Trial Run
72
Tab. 39 Tightening Moment
72
Document Maintenance and Service Work
73
Tab. 40 Logged Maintenance Tasks
73
11 Spares, Operating Materials, Service
74
Note the Nameplate
74
Ordering Consumable Parts and Operating Fluids/Materials
74
Fig. 30 Consumable Parts
74
Tab. 41 Consumable Parts
74
Kaeser Air Service
75
Service Addresses
75
Spare Parts for Service and Repair
75
12.1 Decommissioning, Storage and Transport
76
Commissioning
76
Packing
76
Storage
76
Transporting
77
Safety
77
Transporting with a Forklift Truck
77
Transporting with a Crane
77
Fig. 31 Transporting with a Forklift Truck
77
Disposal
78
Fig. 32 Transporting with a Crane
78
13 Annex
79
Pipeline and Instrument Flow Diagram (P+I Diagram)
79
Dimensional Drawing
82
Electrical Diagram
86

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