S1_2300Manual Booster

SERVICE MANUAL USEReciprocating CompressorModel: N 753 --- G 145 psi / 500 psiGL---Nr.: N753---G---1.2300.20570---02---40---YD 01

Part No.: 1.2300.20570Serial No.:

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Table of ContentsChapter --- Page

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1 Technical Specification 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Booster Unit 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Noise Level 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Compressor Block 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Drive Motor 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Electrical Connection 1 --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Inlet Pressure Switch Setting 1 --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7 Safety Relief Valve Setting 1 --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8 Installation Requirements 1 --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9 Greasing the Electrical Motor 1 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10 Oil Recommendations 1 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11 Dimensional Drawing 1 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety Regulations 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Symbol and Identification 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.1 Warning notices 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Miscellaneous notices and symbols 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 General Safety Precautions 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Additional Safety Precautions 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Electrical Power Supply 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Spare Parts 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 Environmental Protection 2 --- 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 General 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Proper Use of the Compressor 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Improper Use 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Copyright 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Handling the Document 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Transport and Storage 4 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Take the compressor out of service 4 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Packaging 4 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Transport Instructions 4 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Transporting with a fork lift truck or pallet truck 4 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Transport Using a Crane 4 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6 Storage 4 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Design and Function 5 --- 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Components of the Base---Mounted Booster Package 5 --- 15. . . . . . . . . . . . . . . . . . . . . .5.2 Brief Description 5 --- 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Permissible cut ---in period (ED) 5 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Operating States and Control Modes 5 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.1 Operating states 5 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.2 Tasks of the Controller 5 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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6 Installation 6 --- 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Prevention of thermal problems 6 --- 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Installation Instructions 6 --- 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.1 Installing the levelling discs 6 --- 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Installation Instructions 6 --- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Connection of the Compressed Air Supply 6 --- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4.1 Connection to the low---pressure network 1 6 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4.2 Connection to the high---pressure network 2 6 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Electrical Connection 6 --- 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Controller Design 6 --- 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7 Pipe and Instrument Flow Diagram (P & I Diagram) 6 --- 25. . . . . . . . . . . . . . . . . . . . . . . . .6.8 Compulsory Safety and Regulating Equipment 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.1 Starter control box 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.2 Pressure switch 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.3 Flexible hose 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.4 Check valve 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.5 Air inlet filter 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Putting into Operation 7 --- 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 Points to be Observed before Putting into Operation 7 --- 29. . . . . . . . . . . . . . . . . . . . . . .7.2 Points to be Observed before Starting the Compressor Unit 7 --- 29. . . . . . . . . . . . . . . . .7.3 Checklist 7 --- 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4 Direction of Rotation Check 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 Motor Overload Relay Adjustment 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6 Setting the Inlet Pressure Switch 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6.1 Cut---in frequency of the compressor unit from standstill to load 7 --- 33. . . . . . . . . .

8 Operation 8 --- 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 Starting and Stopping the Compressor Unit 8 --- 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2 KAESER CONTROL Safety System 8 --- 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 Shutdown of the Compressor Package by Safety Devices 8 --- 35. . . . . . . . . . . . . . . . . . .8.4 Trouble Shooting: Possible cause --- Remedy 8 --- 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.1 Compressor does not start 8 --- 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.2 Compressor starts with difficulty 8 --- 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.3 Compressor overheating 8 --- 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.4 Compressor runs continuously, discharge pressure not reached 8 --- 36. . . . . . . . . . . . .8.4.5 Whistling noises at the cylinder head 8 --- 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.6 Safety valve blowing off prematurely 8 --- 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.7 Oil consumption of compressor too high 8 --- 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4.8 Compressor unit squealing 8 --- 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Maintenance 9 --- 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 Observe the following rules during all maintenance and servicing work: 9 --- 38. . . . . . .9.2 Regular Maintenance 9 --- 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3 Regular Maintenance of the Prefilter 9 --- 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4 Oil Level Check and Top---Off (Compressor Block) 9 --- 40. . . . . . . . . . . . . . . . . . . . . . . . .


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9.5 Oil Change (Compressor Block) 9 --- 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.6 Cleaning or Replacing the Air Filter 9 --- 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7 Cleaning or Replacing the Check Valve 9 --- 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.8 Change the oil filter in the crankcase vent 9 --- 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.9 Changing the Oil Filter on the Crankcase 9 --- 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10 Clean the aftercooler and check for leaks 9 --- 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.11 Cleaning or Replacing the Dirt Trap 9 --- 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.11.1 Check and clean the dirt trap in the inlet line 9 --- 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.11.2 Check and clean the dirt trap on the crankcase 9 --- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12 Checking the V---Belt Tension 9 --- 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13 Tensioning the V---belt(s) 9 --- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14 V---Belt Change 9 --- 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15 Testing the Safety Relief Valve 9 --- 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16 Greasing the Electric Motor 9 --- 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17 Clean the nozzle 9 --- 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18 Check or Replace the Cylinder Heads and Valves (Compressor Block) 9 --- 54. . . . . . . .9.19 Maintenance Schedule 9 --- 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Spare Parts and After Sales Service 10 --- 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1 Service Parts and Maintenance Parts 10 --- 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2 Ordering Spare Parts 10 --- 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Appendix 11 --- 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 Electrical Diagram 11 --- 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 Temperature Sensor Technical Specification 11 --- 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.1 Application 11 --- 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.2 Function 11 --- 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Specification

1 --- 1

1 Technical Specification

1.1 Booster UnitModel N 753 --- G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overall weight 1565 lbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum permitted pressure ratio 4.5:1. . . . . . . . . . . . . . . . . . . .(see permitted duty cycle, chapter 5.3)Diagrams:Dimensional diagram 1.2300.20500. . . . . . . . . . . . . . . . . . . . . . . .Electrical diagram SKK---U0927.00 & SKK---U0947.00. . . . . . . . .P & I flow diagram FKKN753---GST---00090.02. . . . . . . . . . . . . . .(Pipework and Instrument flow diagram)

1.2 Noise LevelNoise level to CAGI---Pneurop 80 dB(A). . . . . . . . . . . . . . . . . . . . . . . . . .at 1 m distance (free sound field measurement)

1.3 Compressor BlockModel N 753. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Displacement 35.3 cfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Capacity CFM (FAD) 327.4 cfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .at 500 psig working pressureInlet pressure 110---145 psig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum working pressure 500 psig. . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum duty cycle:Pressure ratio 3 100 %. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ratio 3 (load 60 min., idle 15 min.) 80 %. . . . . . . . . . . .Number of cylinders 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speed 1250 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil capacity 4.2 qts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil top ---off quantity 0.2 qts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Drive MotorRated power 40 hp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated speed 3600 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosure rating TEFC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Max. starts per hour 20 times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Wye---Delta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1 --- 2

1.5 Electrical ConnectionMain voltage 460 V 3---phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Full load current FLA 54 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frequency 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommended main disconnect fuses(Dual element or time---delay) 80 A. . . . . . . . . . . . . . . . . . . . . . . . .Recommended power supply cable (Cu multi ---stranded )cross---section 3 AWG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum dual element time---delay fuses are selected according to2002 N.E.C. Article 240---6, 430---52 and Tables 430---52, 430---148 &150.

Select multi---strand copper core wire at 40 C ambient temperatureaccording to 2002 N.E.C. 110---14(c), 220---3, 310---15, Table 310---16,430---6, 430---22, 430---24 and Tables 430---148 & 150.

1.6 Inlet Pressure Switch Setting

3 4 5 6 7 8 9 10 11 123

4

5

6

7

89

10

1112 MDR 43/11

bar

bar

Range of settings forthe inlet pressure switch

Cut---in pressure

Cut--

-o

utp

ress

ure

1.7 Safety Relief Valve SettingSet point 550 psig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Installation RequirementsEnsure 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.

Max. height above sea level at place of installation 3000 ft.. . . . . .(for all heights above please contact authorized KAESER distributor)Min. ambient temperature 40 F. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Max. ambient temperature* 105 F. . . . . . . . . . . . . . . . . . . . . . . . . . .* For higher ambient temperatures the diagram in chapter 5 showing maximum cut---in

duration must be taken into consideration.Recommended minimum compressor space size(floor area x room height) 110 sq.ft. x 8 ft.. . . . . . . . . . . . . . . . . . . . .Ventilation of installation spaceInlet air opening 4.3 sq.ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust air opening 4.3 sq.ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attention!

Attention!


1 --- 3

1.9 Greasing the Electrical MotorRelubricate the compressor motor bearings:Relubricate interval 2000 h*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*operating hoursSee the motor nameplate for the quantity of grease to be used when regreasing.Quantity per bearing ________ oz. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bearing damages caused by the use of other brands of grease are excluded from the war-ranty.

Recommended lithium base saponified bearing grease: Exxon Unirex N 3

EXXON Unirex N3 part numbers:3.5 oz part No.: 9.0915.014.1 oz part No.: 6.3234.0

Replace the compressor motor bearings:Under normal operating conditions, after 36000 h*. . . . . . . . . . . . . .(ambient temperature up to 77 F)Under unsuitable operating conditions, after 20000 h*. . . . . . . . . . .(ambient temperature 78 F or more)at the latest after 8 years. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*operating hours

1.10 Oil RecommendationsLubrication of an air compressor is essential to reliable operation. Carbon and varnish canform in compressor oils. These deposits block the flow of lubricant and cause excessivewear and failure of moving parts. Contamination of the oil can allow the formation of acids,causing extensive internal corrosion. Water may be condensed decreasing the oils lubric-ity.KAESER COMPRESSORS has several lubricants available that are specially formulated tomatch these demands. They feature excellent lubricity, outstanding demulsibility (ability toseparate from water), and long life.

RECOMMENDED KAESER LUBRICANTS

SIGMA

LUBRICANT

DESCRIPTION MAXIMUM RECOMMENDED

CHANGE INTERVAL*

First Oil Change Subsequent OilChange

M---150

S---150

ISO 100 Semi---SyntheticLubricant

ISO 100 Synthetic Lubricant

50 Hours

100 Hours

1,000 Hours

2,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.When high ambient temperatures or dirty conditions are present, oil changes may benecessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oilchange intervals required should be determined through periodic oil analysis.


1 --- 4

M ---SERIES SEMI ---SYNTHETIC LUBRICANTS M---Series SIGMA compressor fluids are the highest quality petroleum lubricants.

M---150 is specially blended to provide reliable performance in KAESER reciprocatingcompressors.

S---SERIES SYNTHETIC LUBRICANTS S---Series SIGMA compressor oils are formulated from the most advanced synthetic

lubricants. These synthetic lubricants begin as high quality petroleum feed stock.They are then refined, processed and purified into fluids with very consistent molecularstructure. These oils are carefully blended to produce extremely lubricants with supe-rior properties. SIGMA synthetic lubricants feature all the advantages of both PAO anddiester fluids.

S---150 lubricant is recommended for compressors operating in ambient temperaturesbetween 40 F and 105 F.

Specialty KAESER LUBRICANTS FG---150 synthetic hydrocarbon based food grade lubricant is designed for use in re-

ciprocating compressors in the application where incidental food contact may occurwith the discharge air. This lubricant meets the requirements of the FDA Regulation 21CRF 178.3570 and is USDA H---1 approved. FG---150 is approved for canning, foodpacking, meat and poultry processing and other applications where incidental foodcontact may occur.

SPECIALTY KAESER LUBRICANTS

(Refer to product information to determine suitability.)SIGMA

LUBRICANT

DESCRIPTION MAXIMUM RECOMMENDED

CHANGE INTERVAL*

First Oil Change Subsequent OilChange

FG---150 ISO 46 Food GradeSynthetic Lubricant

500 Hours 1,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.When high ambient temperatures or dirty conditions are present, oil changes may benecessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oilchange intervals required should be determined through periodic oil analysis.

KAESER synthetic lubricant should be stored in a protected location to prevent contamina-tion. Do not re---use drums; flush and send to reconditioner.Although the KAESER synthetic is not highly flammable, it will burn. While KAESER syn-thetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classi-fied as a fire---resistant fluid. It has a flash point above 460 F. Since the user has total con-trol over the conditions of the compressor lubricant, he assumes total responsibility for itssafe usage.Material Safety Data Sheets are available for each lubricant from your KAESER authorizeddistributors.


1 --- 5

Compatibility:FG---150 is similar to mineral oil in its compatibility with paints, seals, gaskets andhoses. The typical precautions are required when changing over from mineral oil toKAESER synthetic hydrocarbon based lubricant.Never mix lubricants of different types or brands.

When switching from mineral oil to a synthetic oil, the plants system materials must bere---evaluated. Certain plastics are not compatible with synthetic oils. The following is a par-tial list of acceptable and not recommended materials:

ACCEPTABLE NOT RECOMMENDED

VitonHigh Nitrile Buna NTeflonEpoxy PaintOil Resistant AlkydNylonDelrin

CelconNeopreneSBR RubberLow Nitrile Buna NAcrylic PaintLacquerPolystyrene

PVCABS

Polycarbonate bowls can be etched by any synthetic lubricant.We recommend replacement with metal bowls, or the addition of metalguards.

1.11 Dimensional Drawing(see following page)

Attention!

Safety

2 --- 7

2 Safety Regulations

Disregarding this notice can result in serious injury!

Read this service manual carefully and observe cautionary references before putting thecompressor unit into operation and before carrying out any maintenance on the unit.

2.1 Symbol and Identification

2.1.1 Warning notices

Here is a notice warning of danger.

DANGER Here are consequences of ignoring the warning notice.The word Danger indicates that death or severe injury can result fromignoring the notice. Always read and diligently comply with warning notices.

Danger levelsWarning notices indicate three levels of danger identified by the signal word under thedanger symbol.

Signal word Meaning Consequences of ignoring the warningDANGER warns of imminent

threatening dangerdeath or severe injury or serious damage tothe machine

WARNING warns of possiblethreatening danger

death or severe injury or serious damage tothe machine is possible

CAUTION warns of a possiblydangerous situation

light injury or slight damage possible

This symbol is placed before all references to safety where danger tolife and limb can occur during work. It is important in such cases thatthese notices are observed and that extreme care is taken. For theirown protection, all other users must be informed about these safetynotices. Observe general safety and accident prevention regulationsas well as the safety notices given in this service manual.

This symbol is placed by text where considerable attention must bepaid so that directives, regulations, references and correct sequenceof work are adhered to and that damage or destruction of the machineis prevented.

Attention!

Safety

2 --- 8

2.1.2 Miscellaneous notices and symbols

This symbol identifies environmental protection measures.

This symbol indicates actions to be carried out by the user.

This bullet identifies listings.

This warning label identifies hot surfaces:DO NOT TOUCH!

2.2 General Safety Precautions

Work on power driven systems may only be carried out by trained orspecialized personnel.

Work on the electrical equipment of the refrigerated dryer may only becarried out by a qualified electrician or trained personnel under thesupervision of a qualified electrician according to the NEC and any ap-plicable local codes.

Prior to working on electrical systems of the compressor always per-form the following steps in the sequence shown.

1. Lock the main disconnect in the off position in accordance withapplicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart.2. Ensure the package cannot be switched on again

3. Check that no voltage is present

4. Lock the isolation shut---off valve in the closed position and ventall compressed air trapped between the compressor and the isolationshut---off valve in accordance with applicable lock out/ tag out pro-cedures (example: OSHA CFR 29 1910.147).

Unless the Service Manual states otherwise, all pressure lines must bevented or shut off.

Any alterations or reconstruction carried out without the prior writtenauthorization of KAESER COMPRESSORS Inc. will invalidate the war-ranty.

No welding, heat--- treatment or mechanical work may be carried out onpressure retaining conponents, e.g. pipes, air mains, receivers, etc.

Safety devices may not be modified or deactivated.

Signs and labels of reference may not be removed or rendered un-readable.

Attention!

Attention!

Attention!

Safety

2 --- 9

2.3 Additional Safety Precautions

Comply with the following: Do not allow open flame and flying sparks at the installation site. Take necessary precaution when welding on or near the compressor unit to ensure

that sparks or high temperatures cannot cause fire or explosion. Ensure that the compressor unit is supplied only with clean uncontaminated air. Do not allow the maximum ambient temperature to be exceeded (see chapter 1.8),

unless special measures have been agreed upon between the manufacturer and thecustomer.

Perform oil changes according to the service manual or at least once annually. Do not mix cooling oils of different types. Use only cooling oils recommended by the manufacturer (see chapter 1.10). This machine is not explosion---proof.

It may not be operated in areas in which specific requirements with regard to ex-plosion protection are applied.

2.4 Electrical Power Supply

The main power supply and overcurrent protection must be installedby a qualified electrician in accordance with NEC, OSHA and any appli-cable local codes.

Compressor units must be installed with a lockable main disconnectand fuses or other short---circuit and ground fault protection device.

For fuse and wire recommendations, see chapter 1.5

Please note that the conductors, fuses and procedure are Kaesersrecommendations. These recommendations do not supersede otherapplicable codes.

2.5 Spare PartsSafe and reliable operation of the compressor unit is guaranteed only with KAESER originalspare parts and KAESER SIGMA compressor oil.

Attention!

Attention!

Safety

2 --- 10

2.6 Environmental ProtectionCondensate drainage

Condensate accumulating during compression must be drained via asuitable draining system and collected in disposal canisters. The con-densate must be disposed of according to environmental care regula-tions.

Maintenance materials/wear items/replacement parts

Dispose of all used materials and parts accumulating during oper-ation, maintenance and repair of the compressor unit according toenvironmental care regulations!

Disposing of the MachineWhen disposing of a machine, drain out all liquids and remove dirty filters.

Dispose of all used materials and parts accumulating during oper-ation, maintenance and repair of the compressor unit according toenvironmental care regulations!

Take the machine out of service (see chapter 8.1). Drain all oil completely from the machine (see chapter 9.5). Remove dirty filters.Use the services of an approved local disposal specialist to ensure environmentally correctdisposal of the empty machine.

General

3 --- 11

3 General

3.1 Proper Use of the CompressorThe compressor unit is intended solely for the purpose of generating compressed air. Anyother use is considered improper. The manufacturer cannot accept liability for any damagecaused by such improper use; the user alone is liable for any risks incurred.Proper use of the compressor also includes compliance with the installation, removal, ap-plication, operational and maintenance instructions laid down by the manufacturer.

The equipment may only be used or serviced by authorized andtrained personnel.

3.2 Improper Use

Never direct compressed air toward persons. Compressed air is a con-centrated form of energy and as such dangerous to life.

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

Inlet air may not contain any explosive or chemically unstable gas orvapour.

Initial filling of a fully vented air main generally creates very a high rate of flow through airtreatment devices.These devices cannot function correctly under such conditions and compressed air qualitysuffers.KAESER recommends installation of an air main charging system to ensure required airquality.

3.3 Copyright KAESER COMPRESSORS, INC.All rights reserved. No part of this manual may be reproduced in any form without per-mission of KAESER COMPRESSORS, INC.

3.4 Handling the DocumentThe service manual is part of the machine. Keep the service manual safe throughout the life of the machine. Pass the manual on the the next owner/user of the machine. Ensure that all amendments are entered in the manual.

Attention!

Attention!

Transport

4 --- 12

4 Transport and Storage

4.1 Take the compressor out of serviceThe compressor must be correctly taken out of service in preparation for transport. Switch the compressor off (see chapter 8.1).

Electric shock can kill!

DANGER Touching electrically live components can cause serious injury or death.Power and control terminals may still be live when the motor is stopped.

Lock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Seechapter 2.4 for the main disconnect switch.

Wait at least five minutes before checking for electrical voltage. Work carefully.

Isolate the compressor from the air main by closing the users compressed air inletand outlet shut ---off valves. Initial and final pressure gauges must read zero.

Allow the compressor to cool down completely. If the compressor is water---cooled, shut off the water supply, drain the water com-

pletely from the heat exchanger and dispose of it according to environmental regula-tions.

Disconnect all supply lines.

4.2 PackagingAlways observe the instructions in chapter 4.6 when packaging the machine for storage.Use packaging suitable for the intended route if the machine is to be transported further bythe customer.

OverlandThe machine should be protected from mechanical damage by a sturdy crate and frommoisture by plastic sheeting.

By sea or airSpecial packaging instructions can be obtained from KAESER.

Dispose of the packaging according to environmental regulations andrecycle where possible.

Transport

4 --- 13

4.3 Transport InstructionsA fork lift truck or lifting cradle should be used to avoid damaging to the machine.

4.4 Transporting with a fork lift truck or pallet truckIn order to move the machine by means of a fork or pallet truck it must be on a suitablepallet or transport frame.

4.5 Transport Using a Crane

If the compressor unit is transported by a crane the safety regulationsconcerning lifting appliances must be observed.

Do not stand beneath hanging loads.

Do not exceed the maximum permissible lifting weight of the lifting ap-pliance.

Do not excert any side forces on the compressor unit when transport-ing with lifting equipment.

Attention!

Attention!

Transport

4 --- 14

4.6 StorageThe machine must be adequately packed. Store the machine in a dry, frost ---free room. Prevent entry of moisture and condensation.If the equipment is to stand idle for a long period the prescribed measures must be takento avoid damage.If any measures can not be taken, advice should be sought from the authorised KAESERService depot.As an alternative to storage, the equipment can be run once a week for 30 minutes at op-erating temperature to ensure adequate corrosion protection.Otherwise, the measures described under Storage for longer than 6 months are to betaken.

Storage for longer than 6 monthsEnsure the machine is dry and cover in plastic sheeting. Protect the interior with sufficientquantities of desiccant (silica gel or similar).Storage for longer than 12 monthsCarry out the following additional maintenance tasks before putting into operation: change the oil filter (see chapter 9.9), change the oil (see chapter 9.5), have the motor bearings checked by an authorised KAESER service technician.

Storage for longer than 3 years:after 3 years at the latest the complete technical condition of the machine must bechecked before start ---up.

Damage to the machine can occur if the condition is not checked.

CAUTION Have the the start ---up carried out by an authorised KAESER servicetechnician.technician.

Construction and Operation

5 --- 15

5 Design and Function

This booster compressor is an air cooled, oil lubricated compressor using the principle ofsingle stage compression.Compressed air from an air system is drawn in through the inlet port and the collector pipeto the compression chamber of the compressor block. This compressed air is drawn in viathe valve plate in the cylinder head during the downward motion of the piston from the topto the bottom dead center. After the piston has reached the bottom dead center positionthe 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 to the compressed air outlet.

5.1 Components of the Base---Mounted Booster Package

2

134

11

56 81213 14 16 1517

1921

18

222324 910

25

20726

KMZ052211


5 --- 16

1 Inlet port, entry of air from the low---pressure air main2 Compressed air outlet to the high ---pressure network3 Compressor block, compresses the inlet air4 Collecting pipe, collects and smoothes the incoming air5 Aftercooler, collects and smoothes the compressed air and dissipates the heat

through the cooling fins6 Check valve, prevents the escape of inlet air through the filter7 Pressure relief valve, protects the compressor block from excessive pressure8 Inlet valve9 Control valve in the compressed air inlet10 Relief valve, de---pressurises the machine during standstill11 De---watering valve on the compressed air outlet12 Air filter, cleans the intake air during idling13 Electric motor, drives the compressor block14 Casing venting with oil filter15 Crankcase oil filter, cleans the compressor oil flowing through the oil pump integrated

in the crank case16 Oil filler port17 Oil level sight glass18 Oil drain plug19 Dirt trap in the compressed air inlet, cleans the incoming air20 Dirt trap in the oil circuit, protects the oil pump from contamination21 Temperature gauge switch, measures the compressed air discharge temperature and

switches the machine off if the maximum set value is reached22 Oil pressure gauge23 Initial pressure gauge24 Final pressure gauge25 Initial pressure switch, registers the inlet pressure and thereby regulates the swit-

ching on and off of the compressor26 Temperature sensor, measures the block discharge temperature and switches the

machine off if the maximum set value is reached

5.2 Brief DescriptionThe compressor block is driven by an electric motor via V---belts.The compressor block may have one, two or three cylinders.The belt pulley on the compressor crankshaft also serves as a fan to blow a stream of cool-ing air over the machine. Cooling fins on the cylinder and cylinder head dissipate heat.A solenoid ---operated inlet valve is fitted at the compressed air inlet to the block.A pneumatically operated venting valve, coupled with the control valve, is fitted to the after-cooler or base frame to de---pressurise the machine.A further valve ensures de---watering of the pressure system.The oil is pumped through a filter and returned to the crankcase.A pressure switch ensures that the compressor runs only in the permitted initial pressurerange (see chapter 1.6).


5 --- 17

5.3 Permissible cut---in period (ED)

3.4

Ambient temp. 85 F, inlet temp. 95 F

Final temperature [ F]

Upto

100%

duty

cyc

le

Upto

80%

duty

cyc

le

max.

Example

Non

---pe

rmis

sibl

era

nge

Com

pres

sion

ratio

[PB(a

)/P1(a

)]

Ambient temp. 105 F, inlet temp. 115 FAmbient temp. 115 F, inlet temp. 125 F

212 230 248 266 284 302 320 338 356 374 392 410 428

The maximum duty cycle (ED) of the booster is related to the compression ratio (dischargepressure PB absolute / initial pressure P1 absolute), the ambient temperature and the com-pressed air inlet temperature (see diagram).Example:Initial pressure 160 psi (g)Discharge pressure 580 psi (g)Compression ratio: 594 psi (abs) / 174 psi (abs) = 3.4Ambient temperature 105 F, inlet temperature 115 FResults in a duty cycle (ED) of 80 %. Duty cycle (ED) = Duty cycle (ED) is the portion of the total operating cycle that the

unit is under load.

Time under load + stationary time + time unloaded*ED [%] Time under load= x 100 %

* if booster is equipped with load/unload (Dual) control.Note: Duty cycle calculations are typically based on a 1 hour period.


5 --- 18

5.4 Operating States and Control Modes

5.4.1 Operating states LOAD

The inlet valve is fully open. The airend delivers compressed air to the system.The drive motor runs under full load.

IDLINGThe inlet valve is closed. The check valve cuts off the machine from the air main. Theaftercooler is vented.A small volume of air is drawn through the inlet filter into the compressor block and outthrough the venting valve to atmosphere.The drive motor runs without load and draws little current.

STANDSTILLThe inlet valve is closed. The check valve cuts off the machine from the air main. Theaftercooler is vented.The drive motor is stopped.

5.4.2 Tasks of the ControllerUsing the selected control mode, the controller switches the compressor between its vari-ous operational states in order to maintain system pressure between the set minimum andmaximum values.

DUALIn DUAL control the compressor normally runs at full load and idle to maintain systempressure between the set minimum and maximum values.When the maximum pressure is reached the machine switches to idle running.When the preset idling time has elapsed the machine is stopped.The shorter the idling time setting, the sooner and more frequently the motor is stopped.The permitted starting frequency of the motor must not be exceeded.

pmax

pmin

Full load

StandstillMo

tor

pow

er

Pre

ssu

re

Time

t1 t2

1 2 3 4 5

Idle

Installation

6 --- 19

6 Installation

6.1 Prevention of thermal problems Ensure adequate air inlet and outlet appertures in the room (see chapter 1.8). 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 InstructionsTo ensure sufficient cooling of the compressor unit the specified minimum compressorlocation size, minimum distance to the walls and minimum size of the ventilation inlet andexhaust openings must be complied with (see chapter 1.8).The cooling air flow of the compressor unit is not greatly influenced in smaller locationseven if the door is opened, if the air flowing in through the door takes the shortest route tothe exhaust opening without flowing around the compressor.Safe operation of the compressor unit is only guaranteed if the ambient temperature re-mains within the limits stated in chapter 1.8).If the machine is installed together with other plant (compressors, refrigerationdryers, etc.), then under no circumstances may the hot cooling air discharged fromthat other plant be directed to the cooling air inlet end of the machine.

19.7

31.5*

Dimensions in inches

Inlet opening

* Recommendedminimum doorwidth to allowentry ofcompressor

Exhaustopening

Installation

6 --- 20

6.2.1 Installing the levelling discsLevelling discs are needed if a compressor is not standing level or if the antivibration padsare not all equally loaded.

Drive a fork lift carefully under the compressor and lift slightly.

There is a danger of tipping because of the centre of gravity and thecompressor weight.

1

3

42

1 Antivibration pad2 Threaded hole for fixing the

antivibration pad under the compressor3 Holes for rag bolts to fix the

antivibration pad to the floor4 Compensating disc

to correct for uneven floor level

Attention!

Installation

6 --- 21

Determine the positions where the levelling discs are to be installed. Lift the compressor. Remove the screws retaining the corresponding antivibration pads. Insert the levelling disc between the compressor and the pad. Re---secure the pad.

If the compressor is equipped with a sound enclosure the rear panel ofthe enclosure must be fitted before the antivibration pads are screwedto the floor.

Position the compressor and fix to the floor with rag bolts.

6.3 Installation InstructionsThe machine must be installed in accordance with the following diagram to ensure correctoperation with other plant.It must be possible to isolate the machine by means of shut ---off valves on the inlet andoutlet to enable maintenance work to be carried out with the machine de---pressurised.

6.4 Connection of the Compressed Air SupplyThe booster package is connected to an existing air system by a flexible hose.A shut off valve must be connected between the air system and the inlet of the boostercompressor.The discharge outlet has to be connected to the consumers via a flexible hose or pipeworkwith check valve.The location of the compressed air inlet and outlet connections is shown in chapter 1.11.

Separator

Airreceiver 1

Airdryer 1

Rotary screwcompressor

Airreceiver 2

Airdryer 2Booster

Prefilter

Low pressure main 1 High pressure main 272.5---190 psig up to 650 psig

Low pressureconsumers

High pressureconsumers

Option

Fine filter 1

Fine filter 2

Attention!

Installation

6 --- 22

6.4.1 Connection to the low---pressure network 1Connection to the low---pressure network must be via a swans neck pipe. A prefilter, toremove dust and condensate from the inlet air, is essential for reliable operation of the ma-chine. The connection between the prefilter and the machine must be made with a flexiblehose.Inlet air quality:

max. moisture 100% (drip free);

solid particles 1 m.If there is no dryer between the machine and the air receiver in the low pressure networkthen it is imperative that the prefilter is fitted with an automatic drain valve.Furthermore, the machine must run in idle for approximately three minutes before shut-down to ensure that the inlet pipe is dry (idle control must be fitted).

1

32

4 5

KGB005021

1 Compressed air line2 Low pressure network3 Hose line4 Prefilter5 Machine (low pressure compressed air inlet)

6.4.2 Connection to the high---pressure network 2A flexible hose must be used to connect tie machine to the high---pressure network.

65

KFB008221

5 Machine (low pressure compressed air inlet)6 Machine (high pressure compressed air outlet)

Installation

6 --- 23

6.5 Electrical Connection

The main power supply and overcurrent protection must be installedby a qualified electrician in accordance with NEC, OSHA and any appli-cable local codes.

For fuse and wire recommendations, see chapter 1.5.

The control box is wired ready for connection to the main supplies. Feed the supply cablewith cores marked L1, L2, L3 and PE through the cable inlet in the base frame of the con-trol box and connect to the terminals marked L1, L2, L3 and PE in this box.

Maximum dual element time---delay fuses are selected according to1996 N.E.C. Article 240---6, 430---52 and Tables 430---148 & 150.

Select multi---strand copper core wire at 40 C ambient temperatureaccording to 1996 N.E.C. 110---14(c), 220---3, 310---15, Table 310---16,430---6, 430---22 and Tables 430---148 & 150.

Wire temperature rating:

1.25 x FLA(see chapter 1.5)

wiretemperature rating

correction factorfor 40 C

100A 60 C 0.82 100A 75 C 0.88

6.6 Controller DesignA controller that complies with EN 60 204 must be provided for connection to the powersupply.The machine is fitted with a solenoid control valve that holds the pneumatic inlet valveclosed when not energised. The solenoid valve only opens when the air inlet is subjectedto a pressure at or above the cut ---in setting of the initial pressure switch (see chapter 1.6).A number of components are wired together in the terminal box fixed to the compressor(see diagram in chapter 11.1).Six cables are fed into the terminal box (1):

1, 2, 3 temperature sensors, switching in series(the machine shuts down if one of the sensors fails or a maximum temperaturevalue is exceeded).

4 Oil pressure switch (17.5psig).5 Pressure switch for monitoring initial pressure.

6 Control valve (solenoid directional valve on the compressed air inlet)

Two cables are led out from the connection box:

1 Cable for the temperature sensors.

1 Cable ((oil pressure switch, pressure switch for monitoring initial pressure, initialpressure valve)

Attention!

Installation

6 --- 24

The additional electrical components required for the controller should be designed ac-cording to the corresponding motor power (see chapter 1.4).The lines from the motor and the terminal box are connected in the controller and the fol-lowing should be noted:--- the oil pressure switch (17.5 psig) must be bridged in the motor run---up phase and

must switch the compressor off at a pressure of < 14.5 psig.--- the pressure switch that monitors initial pressure must switch the compressor on at a

pressure higher than pON and into idle running at a pressure lower than pOFF (seechapter 1.6).

The switch for monitoring initial pressure is factory set (see chapter 1.6)and should not be adjusted.If a final pressure is needed lower than the initial pressure setting, how-ever, the setting can be changed (see chapter 7.6).

The ratio of initial to final pressure should not be higher than 1 : 4.5

If the pressure in the inlet line during the load phase falls below pOFF the compressor willbe switched by the pressure switch to idle running.If, during offload running, the pressure in the inlet line falls below pOFF, the compressor willonly switch to load again when pressure pON is reached.

Pressure switch for monitor-ing initial pressure.

System pressure switchfitted by the user

Compressor

p > pON pmin < p< pmax starts up

p > pOFF p < pmax runs under full load

p > pOFF p = pmax switches to idle running

p > pOFF p = pmin switches to full load running*)

p < pOFF pmin < p< pmax switches to idle running *)p < pON Pmin < p< pmax remains or

switches to idle running *)* ) It is useful to record these alarms in the controller and indicate by a signalExample of a machine with 145 psig initial pressure and 650 psig final pressure:pON --- cut ---in pressure of the inlet pressure monitoring switch (e.g. 145 psig)pOFF --- cut ---out pressure of the inlet pressure monitoring switch (e.g. 130 psig)pmin --- cut ---in pressure of the air system pressure switch (user) (e.g. 610 psig)pmax --- cut ---out pressure of the air system pressure switch (user) (e.g. 650 psig)--- The PTC sensors must shut down the compressor if a temperature of 374 F is re-

ached, even if only one sensor registers this temperature (series wired). The sensorconnections must be secure against wire breakage.

--- The adjustable temperature gauge switch (2) has volt ---free contacts that can be usedin the controller.

The compressor components are arranged in accordance with the P & I diagram.

Attention!

Installation

6 --- 25

1

32

45

KFB010421

1 Terminalbox2 Discharge temperature gauge3 Pressure gauge (Oil pressure)4 Pressure gauge (Pre ---pressure)5 Pressure gauge (Discharge pressure)

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

Installation

6 --- 28

6.8 Compulsory Safety and Regulating EquipmentSafety and regulating equipment is supplied in a separate packageand must be installed by the user to ensure safe operation of thebooster unit.

6.8.1 Starter control boxThe control box contents the control equipment of the booster unit like motor starter, over-load relay and KAESER CONTROL. The starter control box has to be connected to thebooster package according to the wiring diagram in chapter 11.

6.8.2 Pressure switchThe pressure switch must be fitted for the regulation of the compressed air demand. Thispressure switch is normally fitted on the corresponding air receiver and regulates thebooster between the cut ---out and cut ---in pressures.

6.8.3 Flexible hoseThe flexible hose is used to connect the booster package with an existing air system (airreceiver or pipework).

6.8.4 Check valveTo prevent the compressed air from flowing back into the compressor block, the checkvalve must be fitted between the booster package and the air receiver.

The size of the check valve depends upon the maximum working pres-sure (see chapter 1.3) and the cross---section of the connection to theair system (see dimensional diagram) from the compressor.

6.8.5 Air inlet filterTo ensure that the booster package is used only with clean air the air filter has to be fittedto the air inlet connection.

safetyrelief valve main discon-

nect switch

starter control box

booster package

air fil-ter

high pressuretank with drain

trap

high pres-sureswitch

checkvalve

flexiblehose

existingair sy-stem

highpres-sureair sy-stem

shut---offvalve

Terminal box

Attention!

Attention!

Initial Start

7 --- 29

7 Putting into Operation

7.1 Points to be Observed before Putting into OperationEvery compressor unit is given a test run at the factory and carefully checked before ship-ment. The test run confirms that the compressor unit conforms to the specification dataand runs perfectly. However, independent of the checks made at the factory, the com-pressor unit could be damaged during transport. For this reason, we recommend that thecompressor unit is examined for such possible damage. Observe the compressor unitcarefully during the first hours of operation for any possible malfunction.

Important functional components in the compressor unit (such ascheck valve, safety relief valve and solenoid valve) are adjusted andfitted to factory standards and specifications. Alterations to these com-ponents are not allowed without prior written authorization from themanufacturer.

Do not disassemble the check valve, safety relief valve and solenoidvalve. They are heavily spring loaded.

7.2 Points to be Observed before Starting the Compressor UnitANY NON---OBSERVANCE OF THIS OR OTHER REFERENCES (WARN-ING; ATTENTION; DANGER) CAN LEAD TO ACCIDENTS CAUSING IN-JURY TO PERSONS OR DAMAGE TO EQUIPMENT.

The compressor unit starts automatically after a power failure provid-ing the line pressure is lower than the setting on the air pressureswitch.

Do not operate the compressor without belt guards or open doors asinjury to persons could occur from the drive belts and electrical equip-ment.

Remove all packaging materials, tools and transport securing devices on and in thecompressor unit.

It is expected that the user employs safe working techniques and that all lawful operat-ing and safety regulations are followed when operating this compressor unit.

The operator of this compressor unit is responsible for its safe operating condition. Do not operate this compressor unit in locations where heavy dust conditions, poison-

ous or inflammable gases could exist. Do not connect the compressor unit to a supply voltage other than that stated on the

nameplate. Install the compressor unit in a location not subject to freezing temperatures. The air

temperature requirements at the air intake must be complied with (see chapter 1.8). During installation of the compressor unit, ensure that a distance of at least 19.7 is

kept between the air intake of the unit and any wall.

Lock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart.Check all screws on the electrical connections for tightness andtighten if necessary (carry out this check again after 50 hours of oper-ation).

Attention!

Initial Start

7 --- 30

7.3 Checklist Is the floor at the place of installation level, solid and load---bearing?

yes no Ist der Raum gro genug fr die Maschine oder deren Komponenten?

yes no Are inlet and exhaust air apertures available in sufficient size and number?

yes no Are all components easily accessible?

yes no Is the power supply cable of sufficient cross---section and the fusing adequate?

(have the electrical connection carried out by a qualified electrician familiar with localconditions)

yes no Are shut off valves on the compressed air inlet and outlet fitted by the user?

yes no Are flexible connecting hoses fitted between the machine and the compressed air lines?

yes no Have all screws, bolts and electrical connections been checked for tightness?

yes no Has the oil level in the compressed been checked?

yes no Has the user installed a lockable main switch compatible with the motor starting char-

acteristics? yes no

Has the setting of the drive motor overload current trip been checked? yes no

Have you ensured that there are no other air components located in the machines ex-haust air flow?

yes no Has the operator been instructed in safety procedures and shown how to operate the

machine? yes no

If the aftercooler is water---cooled, has the supply of water been ensured? yes no

Is the power supply as specified on the nameplate? yes no

Initial Start

7 --- 31

7.4 Direction of Rotation Check Check the direction of rotation of the compressor block by switching the compressor

unit on for a short period. If the direction of rotation does not coincide with the arrowlocated on the fan guard, change over terminals L1 and L2.

7.5 Motor Overload Relay AdjustmentLock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Seechapter 2.4 for the main disconnect switch.

The relay is set to the standard adjustment at the factory.Compressor motor: Wye---delta startIn the Wye---delta configuration the phase current is fed through the motor overload relay.This phase current is 0.58 times the nominal motor current.For the nominal motor current see motor nameplate.

Adjustment:The value can be set to a maximum of 10% higher than the calculated phase current toprevent the overload relay from tripping under voltage fluctuations.When the fault is removed the compressor can be started again by pressing the reset but-ton on the overload protection trip.

7.6 Setting the Inlet Pressure Switch


See chapter 1.6 for pressure switch factory setting and pressure diagram.

Compressed air can cause injury!

WARNING Serious injury can result from loosening parts under pressure. Isolate the machine from the air main by closing the userscompressed air inlet and outlet shut ---off valves.

Do not adjust pressure switch unless it is mounted and pressurized.Do not set the maximum cut---out pressure higher than the maximumgauge working pressure (see chapter 1.1).

Attention!

Initial Start

7 --- 32

1

5--- +

P

+--- P

3

4

KFB003521

1 Cap 4 Adjusting screw p3 Adjusting screw P 5 Screw

Shut down the compressor unit (see chapter 8.1).Lock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Seechapter 2.4 for the main disconnect switch.

Unscrew the screws (5) to the right and left of the cover (1). Remove the cover (1) of the pressure switch.To increase the cut---out pressure: Turn the adjusting screw P (3) clockwise using a screwdriver. The red pin on the

pressure scale indicates the pressure. Screw the plug back into the cover of the pressure switch.

To decrease the cut---out pressure: Turn the adjusting screw P (3) counterclockwise using a screwdriver. The red pin on

the pressure scale indicates the pressure. Screw the plug back into the cover of the pressure switch.

To increase the pressure difference between the cut--- in and cut---out pressures: Turn the adjusting screw p (4) clockwise. The black pin on the differential pressure

scale moves in the max direction.

To decrease the pressure difference between the cut--- in and cut---out pressures: Turn the adjusting screw p (4) counterclockwise. The black pin on the differential

pressure scale moves in the min direction.

Replace the cover of the pressure switch.

Replace the cover after every adjustment of the pressure switch andbefore starting the compressor unit.

Initial Start

7 --- 33

7.6.1 Cut--- in frequency of the compressor unit from standstill to loadThe cut ---in frequency of the compressor unit from standstill to load can be changedwithin a limited range by changing the pressure difference between the cut ---in and cut ---out pressures (switching difference). To change the cut ---in frequency the pressure switchmust be adjusted (see chapter 7.6).

See chapter 1.4 for the maximum cut--- in frequency from standstill toload per hour.

Increasing the switching difference causes a decrease in the cut ---in frequency. Decreasing the switching difference causes an increase in the cut ---in frequency.

Attention!

Operation

8 --- 34

8 Operation

8.1 Starting and Stopping the Compressor Unit

Starting the compressor unit Switch on the main disconnect switch (see chapter 2.4). Turn the control switch in the controller to the Start position.

Check for correct direction of rotation when starting the compressorunit (see chapter 7.4).

Stopping the compressor unit

Do not stop the compressor unit with the main disconnect switch.Always start and stop the compressor unit with the control switch inthe controller.

Turn the control switch in the controller to the Stop position. Switch off the main disconnect switch.See chapter 2.4 for the main disconnect switch.

8.2 KAESER CONTROL Safety SystemThe compressor unit is supervised by the KAESER CONTROL safety system.The green LED (1) illuminates when the unit is ready for operation and during operation. Itis not illuminated during an alarm.If an alarm occurs the red LEDs for the supervisory functions (2), (3) and (4) illuminate.

1

234

5

KAESER CONTROL

Oil Pressure

Temperature 1Motor

Temperature 2

Supervisory functions with indication and shutdown:2 Overload protection cut---out for the compressor motor

If an overload occurs, the motor overload relay shuts down the compressor unit (seechapter 7.5).When the malfunction is corrected reset the compressor unit.

Turn the control switch to the 0 position. Press the reset button of the overload protection switch. Turn the control switch to the 1 position.

Attention!

Attention!

Operation

8 --- 35

3 Shutdown by high temperature in the cylinder headThe PTC sensor must shut down the compressor package if the temperature exceeds374 F , i.e. even if only one sensor registers a temperature excess (this is why they areconnected in series). The wiring used to connect the PTC sensors must be open circuitprotected.

When the malfunction is corrected, reset the compressor unit by turning the controlswitch from I to 0.

4 Shutdown by oil pressure switchThe compressor unit is shut down if the oil pressure in the crankcase is excessive or isinsufficient.

When the malfunction is corrected, reset the compressor unit by turning the controlswitch from I to 0.

5 Temperature gauge switch for detection of excess discharge temperature

If a temperature fault occurs the compressor unit is shut down by the temperaturegauge switch. (see chapter 8.3)The compressor is started again after the fault has been removed.

8.3 Shutdown of the Compressor Package by Safety DevicesShutdown by inlet pressure monitoring switch--- The compressor package is shut down if the inlet pressure is insufficient (less than poff).Shutdown by the oil pressure switch--- The compressor package is shut down if the oil pressure upstream of the filter is too

high or too low.

Shutdown by PTC sensor--- If a temperature of 375 F in the cylinder heads is exceeded the compressor package is

shut down by the PTC sensors. The PTC sensors are connected in series so that even ifthe temperature is exceeded in only one cylinder head the compressor package is shutdown.

Switching off the machine via the temperature gauge switch.The compressed air temperature is sensed directly at the discharge port of the oil separa-tor. If it reaches 175 F, the switch inside the temperature gauge will cause the indicatorlight at the KAESER CONTROL (see chapter 8.2) to come on and also shut the compressordown. Search for and correct the malfunction.

Possible malfunctions: Low oil Cooling system fault Ambient temperature too high or too low When the malfunction is corrected, reset the compressor unit by turning the control

switch from I to 0.Then restart the compressor unit (see chapter 8.1).

Operation

8 --- 36

8.4 Trouble Shooting: Possible cause --- RemedyGeneral safety regulations (see chapter 2) and local safety regulationsmust be complied with during trouble shooting and repair procedures.

Starting after a repair (or malfunction):See chapter 7 Putting into Operation.Explanation of symbols for the following fault diagnosis:

1 --- have checked by a specialist.

2 --- contact your authorized KAESER distributor.

8.4.1 Compressor does not start

Possible cause: Remedy:

No motor power supply, fuses blown. Replace the fuses;

1.

8.4.2 Compressor starts with difficulty

Possible cause Remedy

Inlet valve is not opening Change the control valve

Damaged bearings Replace the bearings or fit an exchangecompressor

Piston seized(too little or wrong type of oil)

Change the cylinder and piston(see chapter9.18)

Mains fault (phase dropout) Check the power supply (fuses); 1.Oil level too high Reduce the oil level to the maximum mark

(see chapter 9.4).

8.4.3 Compressor overheating


Ambient temperature too high(over 105 F).

Lower the ambient temperature (see chap-ter 1.8).

Wrong direction of rotation(observe the direction arrow).

Change over L1 and L2 terminals (seechapter 7.4); 1.

The fan cannot draw in air freely. Ensure that inlet air is available for the fan.

Valve plate leaking, varnished or the reedvalves are broken.

Check, clean or replace valve plate; 1und

2.

8.4.4 Compressor runs continuously, discharge pressure not reached


Valve plate gasket defective or wronglyfitted

Fit new gaskets

Valve plate valves varnished up or defective Clean or change the valves(see chapter 9.18)

Operation

8 --- 37

Pressure losses within the unit Brush soapy water on piping and fittings,seal leaks or replace leaking parts

Air demand higher than the capacity of thecompressor

Increase the size of the compressed airsupply

Solenoid valve blowing off constantly, coilburnt out or defective actuation

8.4.5 Whistling noises at the cylinder head


Loose cylinder head bolts or defective gas-kets.

Tighten the bolts or replace the gaskets;

1 and

2.

8.4.6 Safety valve blowing off prematurely


Safety valve blows, even though the cut ---out pressure is not yet reached.

Check that the pressure gauge functionscorrectly, replace if necessary.Check the pressure setting.

Defective valve spring. Replace the safety valve; 1.

Wrong set point. Set 10---15 psig above max. working pres-sure (see chapter 1.1) of the compressorunit;

1.

Safety valve was opened, dirt particlesstuck in valve seat.

Open the safety valve completely for a shortperiod to allow it to blow itself clean.

8.4.7 Oil consumption of compressor too high


Viscosity of oil too low. Fill with correct oil(see chapter 1.10); 1.

Defective crankcase venting system. Clean the crankcase venting system or re-place the filter;

1.

Piston rings worn or damaged. Replace piston rings and cylinder; 2.

Piston rings worn or damaged after only ashort period.

Replace piston rings and cylinder; 2.(ensure that the inlet air is clean, e.g. byusing an air filter with a higher grade of fil-tration).

8.4.8 Compressor unit squealing

Possible cause Remedy

V---belt(s) slipping Tension the V---belt(s)(see chapter 9.12)

Maintenance

9 --- 38

9 Maintenance

9.1 Observe the following rules during all maintenance and servicing work:

Work on power driven equipment may only be carried out by trained orspecialized personnel. Follow all applicable OSHA and local safetyregulations.

The compressor unit restarts automatically after a power failure if theline pressure is lower than the pressure setting on the air pressureswitch.

Lock the main disconnect switch in the off position in accordancewith applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart (seechapter LEERER MERKER for main disconnect switch).Ensure that no maintenance personnel is working on the compressorunit, that all panels are latched back on again and all maintenancedoors are closed before restarting the compressor unit.

To start the compressor unit see chapter 8.1.

Always tighten down any screw connection that has been loosenedduring maintenance work.

The following points must be observed when handling lubricating andcooling materials:

Avoid contact with skin and eyes.Do not inhale vapors and oil mist.Do not eat or drink when handling such materials.Fire, open flame and smoking are strictly forbidden.

Ensure that all lubricants, consumable materials and replacementparts accumulating during operation and servicing of the compressorpackage are disposed of according to environmental regulations.

Attention!

Maintenance

9 --- 39

9.2 Regular Maintenance

Period* Work to be done See chapter

daily check the oil level in the compressor block 9.4

2 and 24 hours afterfirst putting into opera-tion and after changingthe V---belt

check the V---belt tension 9.12

50 hours after first put-ting into operation

check all electrical screw connections for tight-ness and tighten if necessary

7.2

500 hours after firstputting into operation

carry out a compressor oil change 9.5putting into operation

change the crankcase oil filter 9.9

500 hours or at leastannually

check and clean the air filter 9.6annually

check and clean the dirt trap 9.11

check the V---belt tension 9.12

check the safety valve 9.15

clean the solenoid valve jet 9.15Proper interval varies(see chapter 1.10) or atleast annually

carry out a compressor oil change 9.5

1000 hours check and clean the check valve 9.7

clean the air cooler and check for leaks 9.10

2000 hours grease the motor bearings 1.9

change the crankcase oil filter 9.9

check and clean the oil filter 9.8

5000 hours check the cylinder head, piston rings and valvesfor signs of excessive wear

9.18

12000 hours carry out a general overhaul of the compressor 9.18

up to 20000/36000 h,or at least every 8years

Have the drive motor bearings changed by anauthorised KAESER Service agent.

1.9

* The maintenance period can vary depending on the cycle rate and environmentalconditions.

For severe duty (i. e. ambient temperature over 90 F, relative humidity over 90 %, or dirtyenvironment) the maintenance periods should be cut in half.

We highly recommend that a record is kept of the maintenance work done (seechapter 9.19).

Maintenance

9 --- 40

9.3 Regular Maintenance of the Prefilter

Period Work to be done See chapter

Depending on filter clean the prefilter in the inlet pipe see manufac-turers in-structions

If the appropriate cleaning regulations are not observed condensateand dusty compressed air could be sucked in that could lead to de-struction of the booster package.

9.4 Oil Level Check and Top---Off (Compressor Block)Check the oil level daily through the oil sight glass when the compressor unit is shut down.

If the oil level has sunk to the lower mark, top off the oil immediatelyaccording to the oil recommendations (see chapter 1.10).Never top off to a level exceeding the maximum oil mark on the oillevel sight glass.

When topping off the oil always use a strainer or pour the oil directlyfrom the new oil can.

1

2 max.min.

KFB069421

1 Oil top ---up plug2 Oil level sight glass Shut down the compressor (see chapter 8.1).



Remove the crankcase venting plug (1) from the oil filler.Let oil settle a few minutes before filling to the maximum oil level mark.The oil must flow through the crankcase first.

Top off the oil to the maximum mark. See chapter 1.3 for the quantity of oil required fortopping off from the minimum mark to the maximum mark.

Check the sealing ring of the filler plug (1) for damage and then replace the plug. Open the users shut ---off valves when the machine is re---started.

Attention!

Attention!

Attention!

Maintenance

9 --- 41

9.5 Oil Change (Compressor Block)Oil change must be carried out with warm to the touch condition of the compressor unit(Oil temperature approx. 104 F).

Danger of scalding with hot oilDanger of burns from hot components

CAUTION Wear long---arm clothing and gloves. Work carefully.

Change the oil after approximately the first 500 service hours.For oil change requirements see chapter 1.10.If, under unsuitable operating conditions, condensed water is observed in the oil, recogniz-able by the milky color in the oil level sight glass (2), carry out an oil change immediately.

Damage to the machine from unsuitable oil.

CAUTION Never mix different types of oil. Top up only with the same type of oil as already in the machine.

See chapter 1.10 for suitable oils.

1

2 max.min.3

KFB069321

1 Screw plug2 Oil level sight glass3 Oil drain plug

Shut down the compressor (see chapter 8.1).Lock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Seechapter 2.4 for the main disconnect switch.


Isolate the machine from the air main by closing the users compressed air inlet andoutlet shut ---off valves. Initial and final pressure gauges must read zero.

Remove plug (1) from the oil filler port. Prepare a container to catch draining oil.

Danger of explosion from oils and lubricants!

WARNING Danger of explosion from oil mist and vapours. Fire, naked flame and smoken forbidden!

Maintenance

9 --- 42

Catch the used oil and dispose according to environmental regula-tions.

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 anew can of genuine Kaeser oil.

Replace the plug (1) in the oil filler port. Open the users shut ---off valves when the machine is re---started.

9.6 Cleaning or Replacing the Air FilterThe filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre.Do not exceed a maintenance interval of 500 service hours. Replace the complete air filterif the cartridge is heavily contaminated or has been cleaned often.

2431

KFB073821

1 Air filter2 Air inlet3 Filter cartridge4 Snap fastener Shut down the compressor unit (see chapter 8.1).


DANGER Touching electrically live components can cause serious injury or death.Power and control terminals may still be live when the motor is stopped. Wait at least five minutes before checking for electrical voltage. Work carefully.


Unscrew the air filter (1) from the collector pipe. Unhook the snap fastener (4) and open the filter cap.

Clean the filter with diesel fuel in the open air. Observe the regulationsconcerning the handling of combustible fluids.

Attention!

Attention!

Maintenance

9 --- 43

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.

Make sure that the air inlet in the filter cap (2) is facing downwardswhen screwing on the air filter .

Screw on the air filter (1), fit the cap.Replace the complete air filter if the cartridge is heavily contaminatedor has been cleaned often.

Open the users shut ---off valves when the machine is re---started.

9.7 Cleaning or Replacing the Check ValveThe check valve is fitted between the collector pipe and the air filter. It vents the collectorpipe during idle mode.Check and, if necessary, clean the check valve every 500 service hours or at least onceannually.

21 6

53

4

KFB073921

1 Check valve 4 Valve seat2 End plug 5 Spring3 Valve piston 6 Sealing ring Shut down the compressor package (see chapter 8.1).


DANGER Touching electrically live components can cause serious injury or death.Power and control terminals may still be live when the motor is stopped. Wait at least five minutes before checking for electrical voltage. Work carefully.

Isolate the compressor unit from the air system.

System pressure is present up to the check valve when the com-pressor unit is switched off. For this reason, the compressor unit mustbe isolated from the air system (close the users isolation shut---offvalve). If there is no isolation shut---off valve fitted, the complete airsystem must be vented. The pressure gauge must indicate zero psi.

Attention!

Attention!

Maintenance

9 --- 44

Always wear ear protection when lifting the safety relief valve becauseof the loud noise caused by the compressed air blowing off.

Vent the air receiver and the pipework by lifting the upper knurled ring of the safetyrelief valve (1, see chapter 9.15) and blowing off the compressed air.

Check the pressure on the pressure gauge. It must indicate zero psi. Unscrew the plug (2) in the check valve. Clean the valve piston (3) and the valve seat (4). If damage or heavy wear is noticeable replace the valve cone (3), the spring (5) and

the ring (6). Screw the plug (2) in the check valve again. Open the users shut ---off valves when the machine is re---started.

9.8 Change the oil filter in the crankcase ventA constant oil mist is created by the pressure in the crankcase. Because this oil mistshould not be allowed to escape to the open air the crankcase is vented via an oil filter (2)that retains the oil.If the booster unit runs continuously, the oil accumulating in the crankcase venting systemcan increase to the point where it can no longer return to the crankcase.

Do not run the booster unit without the oil filtered crankcase ventingsystem.

The oil filter (2) must be changed every 2000 operating hours.

1

3

4

2

1 Casing venting2 Oil filter element3 Venting cap4 O---ring

Shut down the compressor (see chapter 8.1).


Attention!

Attention!

Maintenance

9 --- 45

DANGER Touching electrically live components can cause serious injury or death.Power and control terminals may still be live when the motor is stopped. Switch off and lock out the main switch. Wait at least five minutes before checking for electrical voltage. Work carefully.

Compressed air can cause injury!

WARNING Serious injury can result from loosening parts under pressure. Isolate the machine from the air main by closing the userscompressed air inlet and outlet shut ---off valves. Check that the initial and final pressure gauges read zero pressure.

Unscrew the venting cap (3).Escaping oil mist is damaging to health.

CAUTION Do not inhale oil mist or vapour.Avoid contact with skin and eyes. Avoid contact with skin and eyes.

Take out the oil filter (2).Dispose of the oil filter in accordance with environmental care regula-tions.

Insert the new oil filter (2). Screw the venting cap (3) back again, checking the correct seating of the o---ring (4)

for the pressure setting. Open the users shut ---off valves when the machine is re---started.

9.9 Changing the Oil Filter on the CrankcaseChange the oil filter after approximately the first 500 service hours

Danger of scalding with hot oilDanger of burns from hot components

CAUTION Wear long---arm clothing and gloves.Work carefully. Work carefully.

It is recommended that the oil filter be changed every 2000 operating hours but in anycase when the oil is changed or if the oil pressure switch shuts down the compressor be-cause of excessive pressure.

Changing the oil filter Shut down the compressor package (see chapter 8.1).


Attention!

Maintenance

9 --- 46

Wait at least five minutes before checking for electrical voltage. Work carefully.

Close the users shut ---off valve between the compressor package and the air main. The compressors oil circulation system vents automatically. The pressure gauge must indicate 0 psig.

1

2

KFB048621

1 Oil filter2 Turn in this direction to remove

Escaping oil mist is damaging to health.

CAUTION Do not inhale oil mist or vapour.Avoid contact with skin and eyes. Avoid contact with skin and eyes.

Twist the used or contaminated oil filter cartridge counter clockwise to remove andcatch escaping oil in a suitable container.

Dispose of the old oil filter and any used, accumulated oil according toenvironmental care regulations!

Clean the face of the combination block with a lint free cloth. Lightly oil the gasket of the new filter cartridge before screwing into position. Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.

Do not use a tool as this may cause damage to the oil filter cartridgeand the gasket.

Check the oil level (see chapter 9.4). Open the isolation shut ---off valve between the compressor package and the main air

system.

Carry out a trial run.

Lock the main disconnect in the off position in accordance with ap-plicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. See chap-ter 2.4 for the main disconnect switch.

Carry out a visual check for leaks.

Attention!

Maintenance

9 --- 47

9.10 Clean the aftercooler and check for leaksCleaning:

Machine damage from contamination

CAUTION Contamination causes overheating and machine damage Check for contamination every 1000 operating hours.

If the outlet temperature of the machine rises to 50 F above the established annual aver-age, the aftercooler should be cleaned by a KAESER service technician.

Leakage check

Machine damage from leakage

CAUTION Damage or complete breakdown can result. Test run after maintenance or service. Carry out a visual check of the machine.

The air aftercooler should be checked for leaks annually.Especial attention must be paid to aging and corrosion of the cooler materials under longterm operating conditions. Condensate can escape from a leakage.

If the cooler is found to be leaking, shut down the machine immediately and remedythe leak.

9.11 Cleaning or Replacing the Dirt Trap

9.11.1 Check and clean the dirt trap in the inlet lineThe dirt trap prevents contamination of the solenoid valve and the air inlet chamber.If problems occur during idle or during unloaded start, clean the dirt trap.It must be cleaned every 500 service hours.

1

2

KFB052921

1 Plug2 Strainer Shut down the compressor unit (see chapter 8.1).


Maintenance

9 --- 48

DANGER Touching electrically live components can cause serious injury or death.Power and control terminals may still be live when the motor is stopped. Switch off and lock out the main switch. Wait at least five minutes before checking for electrical voltage. Work carefully.


Unscrew the plug (1).Never direct compressed air toward persons. Compressed air is a con-centrated form of energy and is as such dangerous to life. Alwayswear personnel protective equipment.

WARNING Serious injury possible. Never direct compressed air at a person! Wo

S1_2300Manual Booster

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