KAESER KCT blue T Series User manual

Operator manual
Reciprocating compressor
KCT blue T
No.: 902350 00E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
www.kaeser.com

Original instructions
/KKW/PDENT 2.10 en SBA-DENTAL-T-ANLAGE
20190503 092636

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 Options ............................................................................................................................. 4
2.3 Weight .............................................................................................................................. 4
2.4 Compressor block ............................................................................................................ 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure switch setting .................................................................................................... 6
2.8 Pressure ........................................................................................................................... 6
2.9 Noise emission [dB(A)] ..................................................................................................... 6
2.10 Motor power and speed ................................................................................................... 7
2.11 Electrical connection ........................................................................................................ 7
2.11.1 Alternating current .............................................................................................. 8
2.11.2 Three-phase power supply ................................................................................. 9
2.12 Network Conditions .......................................................................................................... 10
2.12.1 Supply conditions at 230V / 1 / 50Hz .................................................................. 10
2.12.2 Supply conditions at 400V / 3 / 50Hz .................................................................. 11
2.13 Tightening torques for screws/ nuts ................................................................................. 11
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 12
3.2 Specified use .................................................................................................................... 12
3.3 Improper use .................................................................................................................... 12
3.4 User's responsibilities ....................................................................................................... 13
3.4.1 Observe statutory and universally accepted regulations .................................... 13
3.4.2 Determining personnel ........................................................................................ 13
3.4.3 Complying with inspection schedules and accident prevention regulations ....... 13
3.5 Dangers ............................................................................................................................ 14
3.5.1 Safely dealing with sources of danger ................................................................ 14
3.5.2 Safe machine operation ...................................................................................... 17
3.5.3 Organisational Measures .................................................................................... 19
3.5.4 Danger Areas ...................................................................................................... 19
3.6 Safety devices .................................................................................................................. 19
3.7 Safety signs ...................................................................................................................... 19
3.8 Emergencies .................................................................................................................... 21
3.8.1 Correct actions in the event of a fire ................................................................... 21
3.9 Warranty ........................................................................................................................... 22
3.10 Environment protection .................................................................................................... 22
4 Design and Function
4.1 Machine overview ............................................................................................................ 23
4.1.1 Machine .............................................................................................................. 23
4.1.2 Compressed air dryer ......................................................................................... 24
4.2 Operating points and control modes ................................................................................ 25
4.2.1 Machine operating points .................................................................................... 25
4.2.2 Control modes .................................................................................................... 25
4.3 Safety devices .................................................................................................................. 26
Contents
No.: 902350 00E
Operator manual Reciprocating compressor
KCT blue T i

4.4 Accessories ...................................................................................................................... 26
4.4.1 Sound enclosure ................................................................................................. 26
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 27
5.2 Installation conditions ....................................................................................................... 27
5.2.1 Determining location and clearances .................................................................. 27
5.2.2 Ensuring the machine room ventilation ............................................................... 28
5.2.3 Prevention of thermal problems .......................................................................... 29
5.2.4 Operation in a compressed air network .............................................................. 29
6 Installation
6.1 Ensuring safety ................................................................................................................ 30
6.2 Reporting Transport Damage ........................................................................................... 31
6.3 Fitting the rubber pads ..................................................................................................... 31
6.4 Connecting the machine to the compressed air network ................................................. 31
6.5 Connecting the machine to the power supply .................................................................. 32
6.6 Sound enclosure retrofit ................................................................................................... 32
6.6.1 Dismantling the sound enclosure ........................................................................ 33
6.6.2 Fitting the sound enclosure ................................................................................. 33
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 35
7.2 Instructions to be observed before any commissioning ................................................... 36
7.3 Checking installation and operating conditions ................................................................ 36
7.4 Motor protection ............................................................................................................... 36
7.4.1 Setting the overload protection for three-phase motors ..................................... 36
7.4.2 Resetting the motor overload protection switch for single-phase motors ........... 37
7.5 Checking direction of rotation (3-phase machines only) .................................................. 37
7.6 Starting the machine for the first time .............................................................................. 38
8 Operation
8.1 Switching on and off ......................................................................................................... 39
8.2 Operating hours counter .................................................................................................. 40
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 41
9.2 Faults ............................................................................................................................... 41
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 43
10.2 Maintenance schedule ..................................................................................................... 44
10.2.1 Document maintenance work ............................................................................. 44
10.2.2 Regular maintenance tasks ................................................................................ 44
10.2.3 Regular maintenance tasks ................................................................................ 44
10.3 Maintaining the air cooler or fan cowl ............................................................................... 45
10.3.1 Cleaning the air cooler or fan cowl ..................................................................... 46
10.4 Air filter maintenance ....................................................................................................... 46
10.5 Filter mat maintenance ..................................................................................................... 47
10.6 Drive motor maintenance ................................................................................................. 47
10.7 Checking the pressure relief valve ................................................................................... 47
10.8 Air receiver maintenance ................................................................................................. 48
10.9 Venting the machine (de-pressurising) ............................................................................ 48
10.10 Maintaining the check valve ............................................................................................. 49
10.11 Cylinder head and valves ................................................................................................. 50
10.12 Documenting maintenance and service work .................................................................. 51
Contents
ii
Operator manual Reciprocating compressor
KCT blue T No.: 902350 00E

11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 52
11.2 Ordering replacement parts ............................................................................................. 52
11.3 KAESER AIR SERVICE ................................................................................................... 52
11.4 Replacement parts for service and repair ........................................................................ 53
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 54
12.2 Packing ............................................................................................................................ 54
12.3 Storage ............................................................................................................................. 54
12.4 Transport .......................................................................................................................... 55
12.4.1 Safety .................................................................................................................. 55
12.4.2 Transporting with a forklift truck .......................................................................... 55
12.5 Disposal ........................................................................................................................... 55
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 56
13.2 Dimensional drawing ........................................................................................................ 59
13.3 Electrical diagram ............................................................................................................. 70
13.3.1 Electrical diagram 1 of 3 ..................................................................................... 70
13.3.2 Electrical diagram 2 of 3 ..................................................................................... 77
13.3.3 Electrical diagram 3 of 3 ..................................................................................... 85
Contents
No.: 902350 00E
Operator manual Reciprocating compressor
KCT blue T iii

Contents
iv
Operator manual Reciprocating compressor
KCT blue T No.: 902350 00E

Fig. 1 Location of safety signs .............................................................................................................. 20
Fig. 2 Machine layout ........................................................................................................................... 23
Fig. 3 Compressed air drying ............................................................................................................... 24
Fig. 4 Recommended machine placement and dimensions [mm] ........................................................ 28
Fig. 5 Fitting the rubber pads ............................................................................................................... 31
Fig. 6 Air connection ............................................................................................................................. 31
Fig. 7 Fitting the sound enclosure ........................................................................................................ 33
Fig. 8 Motor overload protection switch ................................................................................................ 37
Fig. 9 Checking the direction of rotation ............................................................................................... 38
Fig. 10 Switching on and off ................................................................................................................... 39
Fig. 11 Operating hours counter ............................................................................................................. 40
Fig. 12 Cleaning the air cooler or fan cowl ............................................................................................. 45
Fig. 13 Air filter maintenance .................................................................................................................. 46
Fig. 14 Filter mat maintenance ............................................................................................................... 47
Fig. 15 Condensate shut-off valve .......................................................................................................... 48
Fig. 16 Venting the machine ................................................................................................................... 49
Fig. 17 Cleaning the check valve ........................................................................................................... 50
Fig. 18 Transporting with a forklift truck ................................................................................................. 55
List of Illustrations
No.: 902350 00E
Operator manual Reciprocating compressor
KCT blue T v

List of Illustrations
vi
Operator manual Reciprocating compressor
KCT blue T No.: 902350 00E

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1
Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Weight ........................................................................................................................................ 4
Tab. 6 Compressor block ...................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 8 Ventilation overview ................................................................................................................... 5
Tab. 9 Pressure switch setting .............................................................................................................. 6
Tab. 10 Pressure specifications .............................................................................................................. 6
Tab. 11 Noise emission [dB(A)] ............................................................................................................... 6
Tab. 12 Power and speed (AC design) ................................................................................................... 7
Tab. 13 Power and speed (Three-phase current design) ........................................................................ 7
Tab. 14 Supply details 230V / 1 / 50Hz ................................................................................................... 8
Tab. 15 Connection data 115V / 1 / 60Hz ............................................................................................... 9
Tab. 16 Connection data 208-230V / 1 / 60Hz ........................................................................................ 9
Tab. 17 Supply details 400V / 3 / 50Hz ................................................................................................... 10
Tab. 18 Network impedance .................................................................................................................... 10
Tab. 19 Network impedance .................................................................................................................... 11
Tab. 20 Inspection intervals according to Ordinance on Industrial Health and Safety ............................ 14
Tab. 21 Danger Areas ............................................................................................................................. 19
Tab. 22 Safety signs ................................................................................................................................ 20
Tab. 23 Re-commissioning after storage ................................................................................................. 36
Tab. 24 Check list of installation conditions ............................................................................................. 36
Tab. 25 Marking ....................................................................................................................................... 39
Tab. 26 Faults and troubleshooting ......................................................................................................... 41
Tab. 27 Regular maintenance tasks ........................................................................................................ 44
Tab. 28 Regular maintenance tasks ........................................................................................................ 45
Tab. 29 Logged maintenance tasks ........................................................................................................ 51
Tab. 30 Compressed air dryer replacement parts ................................................................................... 52
Tab. 31 Machine replacement parts ........................................................................................................ 52
List of Tables
No.: 902350 00E
Operator manual Reciprocating compressor
KCT blue T vii

List of Tables
viii
Operator manual Reciprocating compressor
KCT blue T No.: 902350 00E