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- Premium Compact W 200/4
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KAESER Premium Compact W 200/4 Service Manual
Summary of Premium Compact W 200/4
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Service manual reciprocating compressor premium compact w no.: 9_9418 20e manufacturer: kaeser kompressoren 96410 coburg • po box 2143 • germany • tel. +49-(0)9561-6400 • fax +49-(0)9561-640130 http://www.Kaeser.Com.
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Original instructions /kkw/ppwco 2.00 en sba-premium compact-tragbar 20120822 115136.
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1 regarding this document 1.1 using this document ......................................................................................................... 1 1.2 further documents ........................................................................................................... 1 1.3 copyri...
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5.2 installation conditions ....................................................................................................... 23 6 installation 6.1 ensuring safety ................................................................................................................ 24 6.2 reporting ...
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12.3 storage ............................................................................................................................. 50 12.4 transporting ..................................................................................................................... 50 12.4.1 safety ........
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Contents iv service manual reciprocating compressor premium compact w no.: 9_9418 20e.
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Fig. 1 location of safety signs .............................................................................................................. 18 fig. 2 machine layout ........................................................................................................................... 21 fig. ...
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List of illustrations vi service manual reciprocating compressor premium compact w no.: 9_9418 20e.
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Tab. 1 danger levels and their definitions (personal injury) .................................................................. 1 tab. 2 danger levels and their definition (damage to property) ............................................................ 2 tab. 3 nameplate ..............................
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List of tables viii service manual reciprocating compressor premium compact w no.: 9_9418 20e.
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1 regarding this document 1.1 using this document the operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. ➤ keep the operating manual in a safe place throughout the life of the machine. ➤ supply any successive owner or u...
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Danger these show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "danger" signal word indicates a lethal or severe in‐ jury will occur. ➤ the measures required to protect yourself from danger are shown here. Wa...
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Material here you will find details on special tools, operating materials or spare parts. Precondition here you will find conditional requirements necessary to carry out the task. Here conditions relevant to safety are named that will help you to avoid dangerous situations. ➤ this symbol denotes lis...
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2 technical specifications 2.1 nameplate the model designation and important technical information are given on the machine's nameplate. ➤ enter the data from the nameplate here as a reference. Feature value reciprocating compressor article no. Serial no. Year of manufacture maximum working pressure...
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2.4 ambient conditions installation maximum altitude amsl* [m] 1000 permissible ambient tem‐ perature [°c] 5–35 * higher altitudes are permissible only after consultation with the manufacturer. Tab. 6 ambient conditions 2.5 pressure switch setting specified pressures are factory set. Customer-specif...
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Emission sound pressure level ■ calculated from the measured average sound power level (directive 2000/14/eg, sound meas‐ uring standard iso 3744) according to en iso 11203:1995 6.2.3d at distance d = 1 m, q2 = logarithmic surface ratio: db. Ec type approval: ■ certificate no.: or/2551/sz03 premium ...
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➤ mark the oil that your compressor contains in the table below. Standard oil special oil oil type sae 5 w30 fgp field of application standard oil for all applications except in connection with food‐ stuffs. Specifically for machines in ap‐ plications where the com‐ pressed air may come into con‐ ta...
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2.10.1.1 power supply specifications the following conductor cross-sections (copper multicore) and fusing (industrial fuses, slow blow) are given according to vde 0100, parts 430 and 523 (iec 60364–4–43) for ambient temperatures from 30 °c and laying method c. ➤ the conductor cross-sections should b...
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Rated power supply: 115v±5%/1/60hz premium compact mains fusing [a] supply cable [mm 2 ] current consumption [a] 160/4 — — — 200/4 — — — 250/4 25 3 x 4 15.6 tab. 17 mains supply 115v/1/60hz rated power supply: 127v±5%/1/60hz premium compact mains fusing [a] supply cable [mm 2 ] current consumption [...
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No interference with other devices is to be expected with network impedance less than z max [ohm]. In general, the maximum permissible network impedance will not be exceeded if the ma‐ chine is supplied at the transfer point with a rated current of i equiv . 2.11.1 mains conditions at 230v/1/50hz pr...
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3 safety and responsibility 3.1 basic instructions the machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■ impairments to the machine an...
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3.4 user's responsibilities 3.4.1 observe statutory and universally accepted regulations. This is, for example, nationally applied european directives and/or valid national legislation, safety and accident prevention regulations. ➤ observe relevant statutory and accepted regulations during installat...
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➤ keep to inspection intervals in accordance with the ordinance on industrial safety and health with maximum intervals as laid down in §15. The inspection intervals are laid down in the technical specification for the air receiver. In‐ spection intervals are dependent on the pressure/volume product ...
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3.5.1 safely dealing with sources of danger the following describes the various forms of danger that can occur during machine operation. Electricity ➤ allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out wo...
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➤ make sure all covers and safety guards are in place and secured before re-starting. Temperature ➤ do not touch hot components! These include, for example, compressor blocks, compressed air lines, coolers, motors and ma‐ chine heaters. ➤ wear protective clothing. ➤ if welding is carried out on or n...
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Transport ➤ use suitable lifting gear that conforms to local safety regulations. ➤ allow transport only by personnel trained in the safe movement of goods. ➤ attach lifting gear only to suitable lifting points. ➤ note the centre of gravity to avoid danger of the load tipping over. ➤ make sure the da...
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Maintenance ➤ make sure the machine is disconnected from electrical power and vented before commencing any work. ➤ wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary. ➤ do not leave any loose components, tools or cleaning rags on or in the machine. Decommissioning, s...
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Fig. 1 location of safety signs item sign meaning 1 danger of fatal injury from electric shock! ➤ before beginning any work on electrical equipment: switch off the mains disconnecting device, lock it in the off position and check that the machine is free of voltage. 2 hot surface! Risk of burns caus...
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Sign meaning maintain the air filter regularly. Drain the condensate daily. If automatic condensate drainage is fitted, check the function at regular intervals. Check the oil level regularly and change the oil at the correct intervals. Tab. 25 information signs 3.9 in emergency 3.9.1 correct fire fi...
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➤ wash thoroughly with skin cleaner, then with soap and water. ➤ contaminated clothing should be dry-cleaned before reuse. Inhalation: oil mist may make breathing difficult. ➤ clear air passages of oil mist. ➤ seek medical help if difficulty with respiration continues. Ingestion ➤ wash out the mouth...
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4 design and function 4.1 machine function fig. 2 machine layout 1 air filter 2 compressor block 3 check valve 4 air receiver 5 air receiver pressure relief valve 6 pressure switch 7 electric motor 8 air receiver pressure gauge 9 oil sight glass 10 oil filler port 11 oil drain plug 12 compressed air...
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4.2 operating modes and control modes 4.2.1 operating modes there are two operating modes: ■ load: the compressor block delivers compressed air. The drive motor runs under full load. ■ standstill: no air is compressed. A check valve prevents compressed air flowing back into the compres‐ sor block. T...
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5 installation and operating conditions 5.1 ensuring safety the conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take ...
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6 installation 6.1 ensuring safety follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions disregard of safety notes can cause ...
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6.3 compressed air connection precondition the machine is isolated from the air consumers. Fig. 3 compressed air connection 1 compressed air connection ➤ make the connection to the air main by a flexible pressure line. 6.4 connecting the machine to the power supply machines with a total power rating...
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7 initial start-up 7.1 ensuring safety follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions disregard of safety notes can ca...
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7.2 instructions to be observed before commissioning or re-commis‐ sioning incorrect or improper commissioning can cause injury to persons and damage to the machine. ➤ commissioning may only be carried out by authorized installation and service personnel who have been trained on this machine. Specia...
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7.4.1 resetting the motor overload protection switch for single-phase motors single phase motors are fitted with a thermal overload protection switch that is set to a fixed value. It ensures shutdown of the machine at levels of current above the value set on the motor overload protection. ➤ have the...
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Fig. 5 setting the network pressure 1 canopy 2 screw 3 adjusting screw for upper pressure (cut- out) 4 pressure differential adjusting screw 5 «on/off» switch for direct online start a premium compact 160/4 b premium compact 200/4 / 250/4 / 300/4 1. Danger! Dangerous voltage! Contact with live compo...
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Adjusting the setting function the pressure differential between cut-in and cut- out pressure is to be decreased. ➤ turn the adjusting screw 4 anticlockwise (in the - direction). Tab. 29 changing the pressure switch setting 6. Replace the cover. The motor starting frequency is to be reduced? ➤ incre...
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8 operation 8.1 switching on and off always switch the machine on and off with the on/off switch. The «on/off» switch is located on the pressure switch. Precondition a power supply disconnecting device has been installed by the user. The plastic canopy is in place. Danger automatic restart! Serious ...
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9 fault recognition and rectification 9.1 basic instructions the alarm indications valid for your machine are dependent on the individual equipment. 1. Do not attempt fault rectification measures other than those given in this manual. 2. In all other cases, have the fault rectified by an authorised ...
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Alarm possible cause remedy the machine runs continuously but maximum pressure is not reached. Air filter clogged. Maintain or replace the air filter. Valves* or valve plate between cylinder head and cylinder are leaking or dirty. Contact kaeser service. Outlet valve reed broken. Contact kaeser serv...
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10 maintenance 10.1 ensuring safety follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions disregard of safety notes can cause...
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10.2 maintenance schedule 10.2.1 logging maintenance work the maintenance intervals given are those recommended for average operating conditions. ➤ adjust the maintenance intervals with regard to local installation and operating condi‐ tions. ➤ keep a log of all maintenance and service work. This en...
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10.2.4 regular service tasks ➤ only an authorized kaeser service technician should carry out service work. ➤ when operating conditions are unfavourable (e.G. Dusty or humid atmosphere) or when the equipment is in constant use, have the service work carried out more frequently (shorter inter‐ vals). ...
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The fan cowl can't be cleaned thoroughly? ➤ have stubborn clogging removed by an authorized kaeser service technician. 10.4 air filter maintenance the air filter insert consists of foam. Replace the air filter if it has already been cleaned a number of times. Material compressed air for blowing out ...
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10.6 checking the oil level the oil level can be read off on the oil sight glass. Precondition the machine is switched off. Fig. 10 checking the oil level 1 oil sight glass 2 oil filler and crankcase vent ➤ read off the oil level daily and before each start-up. Result top up when the compressor oil ...
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Fig. 11 topping up the compressor oil 1 crankcase vent 1. Remove the crankcase vent from the oil filler. 2. Top up to bring the oil to the correct level. 3. Replace the crankcase vent. 4. Start the machine and check the oil level again after about 2 minutes, topping up again, if nec‐ essary. 5. Swit...
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Fig. 12 changing the compressor oil 1 oil filler port 2 oil sight glass 3 oil drain plug draining the oil 1. Remove the crankcase vent from the oil filler. 2. Position the oil receptacle. 3. Remove the drain plug and allow oil to drain into the receptacle. 4. Replace the drain plug after making sure...
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The valve opens to protect the machine if the maximum permissible working pressure is ex‐ ceeded. ➤ never operate the machine without a correctly functioning pressure relief valve. ➤ do not adjust the pressure relief valve. Precondition machine switched off under load. The power supply isolating dev...
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Fig. 14 draining condensate 1 condensate drain tap ➤ drain the condensate out daily. Drain the condensate into a suitable receptacle and dispose of according to environmental regulations. 10.11 venting the machine (de-pressurising) even when switched off the machine is still under pressure from the ...
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The pressure gauge does not read 0 bar after venting? Shut-off valve still open. ➤ defective condensate drain. ➤ if manual venting does not bring the oil separator tank pressure gauge to zero: contact the authorised kaeser service. 10.12 maintaining the check valve the check valve is installed in th...
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10.13 maintenance of the pressure switch unloading valve according to the pressure switch version, the relief valve can be cleaned or must be replaced. The unloading valve must be cleaned in the following circumstances: ■ machine starts with difficulty. ■ the machine does not vent after switching of...
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10.14 cylinder head and valves the condition of the valves can be assessed by measuring the air receiver charging time and com‐ paring this with the charging time when the machine was new. Precondition machine at operating temperature. ➤ start the machine and measure the receiver charging time. Resu...
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10.15 documenting maintenance and service work machine number: ➤ enter maintenance and service work carried out in the list. Date maintenance task carried out operating hours signature tab. 34 logged maintenance tasks 10 maintenance 10.15 documenting maintenance and service work 46 service manual re...
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11 spares, operating materials, service 11.1 note the nameplate the nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤ please give the information from the nameplate with every enquiry and order for spares....
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■ energy savings achieved by avoidance of pressure losses, ■ optimum conditions for operation of the compressed air system, ■ the security of genuine kaeser spare parts, ■ increased legal certainty as all regulations are kept to. ➤ why not sign a kaeser air service maintenance agreement! Result your...
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12 decommissioning, storage and transport 12.1 decommissioning decommissioning is necessary, for example, under the following circumstances: ■ the machine is temporarily not needed, ■ the machine is to be moved to another location, ■ the machine is to be scrapped. Temporary decommissioning precondit...
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12.3 storage moisture can lead to corrosion, particularly on the surfaces of the compressor block. Frozen moisture can damage components, valve diaphragms and gaskets. Please consult with kaeser if you have questions to the appropriate storage and commis‐ sioning. 1. Notice! Moisture and frost can d...
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13 annex 13.1 dimensional drawing 13 annex 13.1 dimensional drawing no.: 9_9418 20e service manual reciprocating compressor premium compact w 51.
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13 annex 13.1 dimensional drawing 52 service manual reciprocating compressor premium compact w no.: 9_9418 20e.
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13.2 electrical diagram 13 annex 13.2 electrical diagram no.: 9_9418 20e service manual reciprocating compressor premium compact w 53.
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13 annex 13.2 electrical diagram 54 service manual reciprocating compressor premium compact w no.: 9_9418 20e.