KAESER Premium Compact W 200/4 User manual

Service Manual
Reciprocating compressor
Premium compact W
No.: 9_9418 20E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/PPWCO 2.00 en SBA-PREMIUM COMPACT-TRAGBAR
20120822 115136

1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Weight .............................................................................................................................. 4
2.3 Compressor block ............................................................................................................ 4
2.4 Ambient conditions ........................................................................................................... 5
2.5 Pressure switch setting .................................................................................................... 5
2.6 Pressure ........................................................................................................................... 5
2.7 Sound emission ................................................................................................................ 5
2.8 Motor power and speed ................................................................................................... 6
2.9 Compressor oil recommendations ................................................................................... 6
2.9.1 Compressor oil charge ........................................................................................ 7
2.10 Power Supply ................................................................................................................... 7
2.10.1 Single phase ....................................................................................................... 7
2.11 Mains conditions .............................................................................................................. 9
2.11.1 Mains conditions at 230V/1/50Hz ....................................................................... 10
2.12 Machine duty cycle ........................................................................................................... 10
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 11
3.2 Specified Use ................................................................................................................... 11
3.3 Improper use .................................................................................................................... 11
3.4 User's Responsibilities ..................................................................................................... 12
3.4.1 Observe statutory and universally accepted regulations. ................................... 12
3.4.2 Qualified personnel ............................................................................................. 12
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 12
3.5 Dangers ............................................................................................................................ 13
3.5.1 Safely dealing with sources of danger ................................................................ 14
3.5.2 Safe machine operation ...................................................................................... 15
3.5.3 Organisational Measures .................................................................................... 17
3.6 Safety Devices ................................................................................................................. 17
3.7 Safety signs ...................................................................................................................... 17
3.8 Information signs .............................................................................................................. 18
3.9 In emergency ................................................................................................................... 19
3.9.1 Correct fire fighting ............................................................................................. 19
3.9.2 Treating injuries from handling cooling oil .......................................................... 19
3.10 Warranty ........................................................................................................................... 20
3.11 Environment protection .................................................................................................... 20
4 Design and Function
4.1 Machine function .............................................................................................................. 21
4.2 Operating modes and control modes ............................................................................... 22
4.2.1 Operating modes ................................................................................................ 22
4.2.2 Control modes .................................................................................................... 22
4.3 Safety devices .................................................................................................................. 22
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 23
Contents
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W i

5.2 Installation conditions ....................................................................................................... 23
6 Installation
6.1 Ensuring safety ................................................................................................................ 24
6.2 Reporting Transport Damage ........................................................................................... 24
6.3 Compressed air connection ............................................................................................. 25
6.4 Connecting the machine to the power supply .................................................................. 25
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 26
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 27
7.3 Checking installation and operating conditions ................................................................ 27
7.4 Motor overload protection ................................................................................................ 27
7.4.1 Resetting the motor overload protection switch for single-phase motors ........... 28
7.5 Measuring the air receiver charging time ......................................................................... 28
7.6 Setting the network pressure ........................................................................................... 28
7.7 Setting the pressure regulator .......................................................................................... 30
8 Operation
8.1 Switching on and off ......................................................................................................... 31
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 32
9.2 Alarms .............................................................................................................................. 32
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 34
10.2 Maintenance Schedule ..................................................................................................... 35
10.2.1 Logging maintenance work ................................................................................. 35
10.2.2 Regular maintenance tasks ................................................................................ 35
10.2.3 Oil change interval .............................................................................................. 35
10.2.4 Regular service tasks ......................................................................................... 36
10.3 Fan cowl maintenance ..................................................................................................... 36
10.3.1 Cleaning the fan cowl ......................................................................................... 36
10.4 Air filter maintenance ....................................................................................................... 37
10.5 Drive motor maintenance ................................................................................................. 37
10.6 Checking the oil level ....................................................................................................... 38
10.7 Topping up the compressor oil ......................................................................................... 38
10.8 Changing the compressor oil ........................................................................................... 39
10.9 Pressure relief valve checking ......................................................................................... 40
10.9.1 Air receiver pressure relief valve ........................................................................ 40
10.10 Air receiver maintenance ................................................................................................. 41
10.11 Venting the machine (de-pressurising) ............................................................................ 42
10.12 Maintaining the check valve ............................................................................................. 43
10.13 Maintenance of the pressure switch unloading valve ....................................................... 44
10.14 Cylinder head and valves ................................................................................................. 45
10.15 Documenting maintenance and service work .................................................................. 46
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 47
11.2 Ordering consumable parts and operating fluids/materials .............................................. 47
11.3 KAESER AIR SERVICE .................................................................................................. 47
11.4 Service Addresses ........................................................................................................... 48
11.5 Spares for service and repair ........................................................................................... 48
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 49
12.2 Packing ............................................................................................................................ 49
Contents
ii
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

12.3 Storage ............................................................................................................................. 50
12.4 Transporting ..................................................................................................................... 50
12.4.1 Safety .................................................................................................................. 50
12.5 Disposal ........................................................................................................................... 50
13 Annex
13.1 Dimensional Drawing ....................................................................................................... 51
13.2 Electrical Diagram ............................................................................................................ 53
Contents
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W iii

Contents
iv
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

Fig. 1 Location of safety signs .............................................................................................................. 18
Fig. 2 Machine layout ........................................................................................................................... 21
Fig. 3 Compressed air connection ........................................................................................................ 25
Fig. 4 Motor overload protection switch ................................................................................................ 28
Fig. 5 Setting the network pressure ...................................................................................................... 29
Fig. 6 Setting the pressure regulator .................................................................................................... 30
Fig. 7 Switching on and off ................................................................................................................... 31
Fig. 8 Cleaning the fan cowl ................................................................................................................. 36
Fig. 9 Air filter maintenance .................................................................................................................. 37
Fig. 10 Checking the oil level ................................................................................................................. 38
Fig. 11 Topping up the compressor oil ................................................................................................... 39
Fig. 12 Changing the compressor oil ...................................................................................................... 40
Fig. 13 Checking pressure relief valve on the air receiver ..................................................................... 41
Fig. 14 Draining condensate .................................................................................................................. 42
Fig. 15 Venting the machine .................................................................................................................. 42
Fig. 16 Cleaning the check valve ........................................................................................................... 43
Fig. 17 Maintenance of the pressure switch unloading valve ................................................................. 44
Fig. 18 Consumable parts ...................................................................................................................... 47
List of Illustrations
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W v

List of Illustrations
vi
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Weight ........................................................................................................................................ 4
Tab. 5 Compressor block ...................................................................................................................... 4
Tab. 6 Ambient conditions ..................................................................................................................... 5
Tab. 7 Pressure switch setting .............................................................................................................. 5
Tab. 8 Pressure specifications .............................................................................................................. 5
Tab. 9 Sound pressure level .................................................................................................................. 6
Tab. 10 Power and speeds ...................................................................................................................... 6
Tab. 11 Permissible starting frequency ................................................................................................... 6
Tab. 12 Compressor oil recommendations .............................................................................................. 7
Tab. 13 Compressor oil charge ............................................................................................................... 7
Tab. 14 Mains supply 110V/1/50Hz ......................................................................................................... 8
Tab. 15 Mains supply 230V/1/50Hz ......................................................................................................... 8
Tab. 16 Mains supply 110V/1/60Hz ......................................................................................................... 8
Tab. 17 Mains supply 115V/1/60Hz ......................................................................................................... 9
Tab. 18 Mains supply 127V/1/60Hz ......................................................................................................... 9
Tab. 19 Mains supply 220V/1/60Hz ......................................................................................................... 9
Tab. 20 Mains supply 230V/1/60Hz ......................................................................................................... 9
Tab. 21 Network impedance .................................................................................................................... 10
Tab. 22 Machine duty cycle ..................................................................................................................... 10
Tab. 23 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 13
Tab. 24 Safety signs ................................................................................................................................ 18
Tab. 25 Information signs ........................................................................................................................ 18
Tab. 26 Re-commissioning after storage ................................................................................................. 27
Tab. 27 Checklist of installation conditions .............................................................................................. 27
Tab. 28 Air receiver charging time ........................................................................................................... 28
Tab. 29 Changing the pressure switch setting ........................................................................................ 29
Tab. 30 Alarms and remedies ................................................................................................................. 32
Tab. 31 Regular maintenance tasks ........................................................................................................ 35
Tab. 32 Oil change intervals .................................................................................................................... 35
Tab. 33 Regular service tasks ................................................................................................................. 36
Tab. 34 Logged maintenance tasks ........................................................................................................ 46
Tab. 35 Consumable parts ...................................................................................................................... 47
List of Tables
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W vii

List of Tables
viii
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

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 user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents
Included with this operating manual are additional documents intended to assist in the safe opera‐
tion of the machine:
■ Declaration of Conformity in accordance with applicable directives.
Missing documents can be requested from KAESER.
➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels
➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent threat of danger Will result in death or severe injury
WARNING Warns of possible danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:
1 Regarding this document
1.1 Using this document
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W 1

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.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
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 "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.
Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
These show the kind of danger and its source.
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols
This symbol identifies particularly important information.
1 Regarding this document
1.4 Symbols and labels
2
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

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 lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with screw-in machine feet). Option codes used in this
service manual are explained in chapter CROSS_REFERENCE_FAILED.
Information referring to potential problems are identified by a question mark.
The cause is identified in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.
1 Regarding this document
1.4 Symbols and labels
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W 3
Option H1

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
Inlet volume
Rated voltage
Synchronous speed
Rated power
Ambient temperature
Tab. 3 Nameplate
2.2 Weight
The weight given is the maximum. The actual weight depends on equipment fitted.
Premium compact Weight [kg]
160/4 31
200/4 32
250/4 33
300/4 34
Tab. 4 Weight
2.3 Compressor block
Premium compact Compressor
block type
Theoretical dis‐
place‐
ment [l/min]
FAD at
6 bar [l/min]
Number of cylin‐
ders
160/4 KCC 160 160 98 1
200/4 KCC 200 200 115 1
250/4 KCC 250 250 150 1
300/4 KCC 300 300 175 1
Tab. 5 Compressor block
2 Technical Specifications
2.1 Nameplate
4
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

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-specific settings may differ.
The air receiver is permanently in a pressure band of 20%. Hence, the pressure difference
may not exceed 20%.
Premium compact Cut-in pressure
[bar]
Cut-out pressure
[bar]
Pressure differ‐
ential Δp [bar]
Setting range*
[bar]
160/4 16 20 4 2/5
200/4 7 9 2 3/4
250/4 7 9 2 3/4
300/4 7 9 2 2/4
* Minimum adjustment range: Cut-in pressure / cut-out pressure
Tab. 7 Pressure switch setting
2.6 Pressure
Premium compact Maximum working pressure [bar] Pressure relief valve
activating pressure [bar]
160/4 20 20
200/4 10 11
250/4 10 11
300/4 10 11
Tab. 8 Pressure specifications
2.7 Sound emission
Sound power level
■ in accordance with 2000/14/EG and ISO 3744
2 Technical Specifications
2.4 Ambient conditions
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W 5

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 compact Sound pressure level [dB(A)] Emission sound
pressure level
[dB(A)]
Logarithmic sur‐
face ratio [dB]
Measured Guaranteed
160/4 85 97 72 13.2
200/4 85 97 74 13.2
250/4 86 97 75 13.2
300/4 86 97 75 13.2
Tab. 9 Sound pressure level
2.8 Motor power and speed
➤ Read off the enclosure protection class from the motor nameplate and enter in the table.
Premium compact Compressor
block type
Rated power
[kW]
Synchronous
speed [rpm]
(50 Hz)
Protection rating
160/4 KCC 160 1.1 3000
200/4 KCC 200 1.1 3000
250/4 KCC 250 1.25 3000
300/4 KCC 300 1.5 3000
Tab. 10 Power and speeds
Permissible starting frequency
➤ Take the permissible starting frequency of the motor from the table below.
Rated power [kW] Permissible starting frequency [1/h]
1.1 20
1.25 20
1.5 20
Tab. 11 Permissible starting frequency
2.9 Compressor oil recommendations
The standard compressor oil is SAE 5 W30.
For special applications FGP oil is used and the machine carries a sticker indicating this.
Information on ordering compressor oil is found in chapter 11.
2 Technical Specifications
2.8 Motor power and speed
6
Service Manual Reciprocating compressor
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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‐
tact with foodstuff.
Maximum permissible oil
change interval in operating
hours/years.
1000/2* 1000/2*
Oil contained in my compressor
* Cool to moderate ambient temperatures, low humidity, low to average duty cycle.
Tab. 12 Compressor oil recommendations
2.9.1 Compressor oil charge
Compressor block type Total charge [litres] Topping up volume [litres]
(minimum–maximum)
KCC 160 0.13 0.05
KCC 200 0.13 0.05
KCC 250 0.13 0.05
KCC 300 0.13 0.05
Tab. 13 Compressor oil charge
2.10 Power Supply
Basic requirements
The machine is designed for a power supply conforming to EN 60204–1 (IEC 60204–1), sec‐
tion 4.3.
In the absence of other user-specified conditions, the limits laid down in this standard must be ad‐
hered to.
It is recommended that the user and the supplier reach an agreement on the basis of the
EN 60204-1, Annex B.
Check and adjust for other deployment conditions before commissioning.
2.10.1 Single phase
The machine requires a symmetrical single-phase power supply.
The machine may only be operated from an earthed single-phase supply network.
Further information When connecting to a European 230 V/1/50 Hz power supply the requirements in chapter 2.11 are
also to be observed.
2 Technical Specifications
2.10 Power Supply
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W 7

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 be changed accordingly if other conditions prevail.
Other conditions would include, for example:
■ higher temperature >30 °C
■ cable lengths >20 m
Mains frequency: 50 Hz
Rated power supply: 230V±5%/1/50Hz
Premium compact Mains fusing [A] Supply cable [mm2]Current consumption
[A]
160/4 16 3 x 1.5 13.0
200/4 16 3 x 1.5 13.0
250/4 20 3 x 2.5 15.5
Tab. 14 Mains supply 110V/1/50Hz
Rated power supply: 230V±5%/1/50Hz
If the machine is delivered with a Schuko plug to CEE 7/4 or CEE 7/7, the power socket may be
fused at 16 A (slow-blow).
Premium compact Mains fusing [A] Supply cable [mm2]Current consumption
[A]
160/4 10 3 x 1.5 6.2
200/4 10 3 x 1.5 6.2
250/4 10 3 x 1.5 7.4
300/4 16 3 x 1.5 10
Tab. 15 Mains supply 230V/1/50Hz
Mains frequency: 60 Hz
Rated power supply: 230V±5%/1/60Hz
Premium compact Mains fusing [A] Supply cable [mm2]Current consumption
[A]
160/4 16 3 x 1.5 13.2
200/4 16 3 x 1.5 13.2
250/4 20 3 x 2.5 15.6
Tab. 16 Mains supply 110V/1/60Hz
2 Technical Specifications
2.10 Power Supply
8
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E

Rated power supply: 115V±5%/1/60Hz
Premium compact Mains fusing [A] Supply cable [mm2]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 [mm2]Current consumption
[A]
160/4 16 3 x 1.5 11.3
200/4 16 3 x 1.5 11.3
250/4 — — —
300/4 — — —
Tab. 18 Mains supply 127V/1/60Hz
Rated power supply: 220V±5%/1/60Hz
Premium compact Mains fusing [A] Supply cable [mm2]Current consumption
[A]
160/4 10 3 x 1.5 6.5
200/4 10 3 x 1.5 6.5
250/4 — — —
300/4 — — —
Tab. 19 Mains supply 220V/1/60Hz
Rated power supply: 230V±5%/1/60Hz
Premium compact Mains fusing [A] Supply cable [mm2]Current consumption
[A]
160/4 — — —
200/4 — — —
250/4 16 3 x 1.5 7.8
300/4 20 3 x 2.5 11.2
Tab. 20 Mains supply 230V/1/60Hz
2.11 Mains conditions
The machines listed in the table below are intended for use in changing locations.
2 Technical Specifications
2.11 Mains conditions
No.: 9_9418 20E
Service Manual Reciprocating compressor
Premium compact W 9

No interference with other devices is to be expected with network impedance less than Zmax
[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 Iequiv .
2.11.1 Mains conditions at 230V/1/50Hz
Premium compact Max. permissible mo‐
tor starts [1/h]*
Highest permissible
system impe‐
dance Zmax [Ω]**
Rated current
Iequiv. [A]
160/4 20 0.244 32
200/4 20 0.244 32
250/4 20 0.292 32
300/4 20 0.112 80
* For exceeding the maximum permissible motor starts, please consult the manufacturer.
** Specification related to the sum of impedances in external and neutral lines.
Tab. 21 Network impedance
2.12 Machine duty cycle
Calculating the cycling period
Cycling time = time under load + time at standstill
Calculating the duty cycle:
Duty cycle [%] = time under load
time under load + standstill time x 100
Example:
12 minutes
20 minutesx 100 % = 60 %
The following values are valid for:
■ 20 °C ambient temperature
■ 30 % relative humidity
■ 1013 mbar air pressure
Premium compact Duty cycle [%] Cycle time [min]
160/4 ≤ 70 3–20
200/4 ≤ 70 3–20
250/4 ≤ 70 3–20
300/4 ≤ 70 3–20
Tab. 22 Machine duty cycle
2 Technical Specifications
2.12 Machine duty cycle
10
Service Manual Reciprocating compressor
Premium compact W No.: 9_9418 20E