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R2D2 Manual - Runyon Surface Prep Supply

1. 6 18 KAESER Chapter Page 7 Putting into Operation 7 19 7 1 Points to be Observed before Putting into Operation 7 19 7 2 Direction of Rotation Check 7 19 7 3 Setting up the Overload Protection Trigger 7 20 7 4 Setting up the Pressure Switch 7 21 741 frequency of the compressor unit from standstill to load 7 22 8 OpertallOD nna E 8 23 8 1 Starting and Stopping the Compressor 8 23 8 2 Faults and their Removal 8 23 8 2 1 Compressor does not Start _ 8 23 8 22 Compressor starts with difficulty 8 24 8 2 8 Compressor overheating 8 24 8 24 The motor overload protection triggers after a short period 8 24 8 2 5 The motor overload protection triggers after a long period 8 24 8 2 6 Compressor runs continuously discharge pressure not reached 8 25 8 2 7 Compressor cutting in too often 8 25 8 2 8 Compressor shuts down air escapes constantly the unloading valve 8 5 8 2 9 Air escapes from the unloading valve when the comp
2. 3 9 3 2 tee e dl 3 9 3 3 Compressed Air Treatment 3 9 3 4 E ele Vun el 3 9 3 5 Accompanying Documents 3 10 3 6 Handling the Document 3 10 4 Transport and 4 11 4 1 Take the machine out of service 4 11 4 2 PACKAGING PRETI 4 11 4 3 Transport Instructions 4 12 4 4 Transporting with a fork lift truck or pallet truck 4 12 4 5 Transport Using a Crane _ 4 12 4 6 Storage f dae have yl 4 13 5 Construction and Operation 5 14 5 1 Principle of Compression 5 14 5 2 Short Description dt hace eon tee re tem yam etre te Barren 5 14 5 3 Compressor Control Stop Start Control 5 14 5 4 Components of the Compressor Unit 5 15 6 Installation see TR gieren pean 0 dea 6 16 6 1 Installation Instructions 6 16 6 2 Connection of the Compressed Air Supply 6 16 6 3 Fitting the Antivibration Mounts 6 17 6 4 Electrical Connection
3. R2D2 Dust Collector Instruction manual USA MM WOMAN im 0 Instruction manual R2D2 Index 1 Introduction 2 Machine applications 3 EU Declaration of Conformity 4 Description of the machine 5 Safety 6 Operation 61 Variations of the dust collection 6 1 1 Operation with the container version 6 1 2 Operation with the bag version 7 Maintenance 71 Belt drive 7 2 Compressor 7 3 Water separator 7 4 Filter cartridges 8 Technical data 9 Appendix CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne info contecnorthamerica com www contecnorthamerica com 86 6 10 NIU 10 10 10 sl 2 11 CONTEC 2012 Instruction manual R2D2 23 T C 1 Introduction CONTEC would like to thank you for deciding to purchase the R2D2 dust collector The R2D2 has been specially developed for connection to floor preparation machinery such as mobile blast machines concrete planers and floor grinders to enable a dust free operation Even huge quantities of dust can be handled by the R2D2 This means the R2D2 is suitable for use with high performance machinery In the CONTEC product range the R2D2 is specially used for the MODUL 350 and ELGATOR mobile shotblasters and the OMEGA 700 floor grinder The R2D2 can be adapted for a wide range of applications not only limited to the construction industry In t
4. 2 bar Safety Valve Setting Opening pressure 11 bar Installation Requirements Max height above sea level at place of installation 1000 m Min ambient temperature 5 C Max ambient temperature 35 C Recommended Oil Craftsmen s compressors are filled with the highly suitable oils listed below Description Oil sort of the maximal permissible material Viscosity group fluid change interval number in operating hours 0 51 VG 5 DIN 51562 years Cool to moderate ambient temperatures low humidity high duty cycle KAESER COMPRESSORS 1 10 Air Receiver Charging Time Air receiver charging time to 3 8 bar 0 min 50 5 1 11 Dimensional Drawing see following page Technical Specification 10029367 0 00 KAESER KOMPRESSOREN Nm ci KC 350 40 D Ersatz f r Geiger Schaef1 18 09 2003 Freigeg 18 09 2003 T HT i d g 9 un uapJem 0 2 as am 48811805 ur sapo uaBunB DJ IAJ A 100181 nz JNU uajJnp auiaJsKs BunpueAJaA Ja Japo
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6. Restarting after a fault see chapter 7 Initial Start up Explanation of symbols in the following faultfinding help gt 1 have checked by a specialist 2 contact KAESER service support Compressor does not start Possible cause Remedy No motor power supply fuses blown Replace the fuses lt gt 1 Contact in pressure switch defective Renew the pressure switch gt 1 Motor overload protection triggered Check the setting see chapter 7 3 gt 1 KAESER COMPRESSORS 8 2 2 8 2 3 8 2 4 8 2 5 Compressor starts with difficulty Possible cause Unloading valve at the pressure switch not opening Damaged bearings Pistons siezed no oil or wrong oil Power supply fault 2 phase running Oil level too high Compressor overheating Possible cause Ambient temperature too high over 40 C Wrong direction of rotation observe the direction arrow The fan cannot draw in air freely Valve plate leaking coked or the valve reeds are broken Operation Remedy Renew the unloading valve see chapter 9 10 1 Renew the bearings or fit an exchange compressor 2 gt 2 Check the power supply fuses 1 Reduce the oil level to the maximum mark on the oil level sight glass see chapter 9 3 Remedy Lower the ambient temperature see chap ter 1 8 Change over L1 and L2 terminals see chapter 7 2 1 Ensure that inlet air is available
7. BunjraqumJaA uantjanuasure 80115005 Japo ua doy JapuaAJaA U DJ A WQN JNU Bunuuprez u buni puy 3 NZ PUN JnDJ1J AUD nz els unjua i3 58421811 435510 sasun em aim 2 2 1 KAESER COMPRESSORS Safety Safety Regulations A Disregarding this notice can result in serious injury This manual should be read and the instructions it contains followed before initial start up and before carrying out maintenance work The machine is constructed to the latest technological standards and to accepted safety regulations Despite this fact physical danger to the user or third parties or damage to the machine and other property exists Use the machine as specified according to the service manual and if it is in perfect technical order Repair defects that could degrade safety or have them repaired immediately Explanation of Symbols and References A This symbol is placed before all regulations concerning safety where danger to life and limb can occur during work It is especially import ant that these regulations are observed and that extreme care is taken For their own protection inform all other users of these safety regula tions Observe all g
8. The machine design is not subject to 97 23 CE directive on pressure equipment see separate Declaration of Conformity Technical documents are archived with the manufacturer in accordance with 2000 14 CE m Cobu rg 03 03 2003 Location Date Wector KAESER KOMPRESSOREN GmbH Tel 49 9561 640 0 Gesch ftsf hrung Dipl Ing Carl Kaeser Dipl Wi Ing Thomas Kaeser Sitz Carl Kaeser Str 26 D 96450 Coburg Fax 49 9561 640 130 RG Coburg 292 USt IdNr DE 132460321 rAtbdoku ce erklarungen k_2003 03 k006 k006_e doc KAESER Chapter Page 1 Technical Specification 1 1 1 1 Compressor Unit 1 1 1 2 Sound emission s 2i 1 1 1 3 1 1 1 4 Electrical Connection 1 1 1 5 Drive ord 1 2 1 6 Air Main Pressure Switch Setting 1 2 1 7 1 2 1 8 1 2 1 9 Recommended 1 2 1 10 Air Receiver Charging Time 1 3 1 11 Dimensional Drawing 1 3 2 Safety Regulations Age vi cocer esc RR rx 2 5 2 1 Explanation of Symbols and References 2 5 2 2 Safety NOI8S ur as ee 2 6 2 3 Electrical 2 7 24 5 6 m 2 8 2 5 3 0 2 8 3 General NR rudes 3 9 3 1 Correct Use of the Compressor
9. Water separator Dust ports Left 70 mm Right 125 mm CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com CeNTEC Instruction manual R2D2 E Picture 7 Picture 8 Dust bin bag version Dust bin container version Picture 9 Picture 10 Dust bin lifting device Phase inverter Picture 11 Picture 12 Plug and socket Belt drive Picture 13 Electric and air pressure ports Picture 14 Clamp for dust bin CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne info contecnorthamerica com www contecnorthamerica com CONTEC 2012 Instruction manual R2D2 E P T C 5 Safety Attention The R2D2 dust collector is constructed according to existing safety rules and regulations These technical precautions should not be removed or changed under any circumstances While operating the machine the following points should also be kept in mind 1 Disconnect the machine before commencing any servicing or maintenance work however menial Never unplug the machine while it is still running This notice can be found in every manual but in nearly every part of the R2D2 high electrical currents are transmitted The danger of injury is therefore not only from electric shock but also from moving parts of the machine 2 Never wear loose or badly fitting
10. longer than 50 metres the cross section of the supply cables and the fuses must be checked and selected according to DIN VDE 0100 and to the regulations of the local electricity supply author ity See chapter 1 4 for details of the cable cross sections and mains fuses 6 8 KAESER COMPRESSORS 7 1 7 2 Initial Start Putting into Operation Points to be Observed before Putting into Operation Every compressor unit is given a test run in the factory and carefully checked before ship ment The test run confirms that the compressor unit conforms to the specification data and 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 the compressor unit is examined for such possible damage Observe the compressor unit carefully during the first hours of operation for any possible malfunction Attention Attention A Work on power driven systems may only be carried out by trained or specialised personnel Work on the electrical system and equipment of the compressor unit may only be carried out by a skilled electrician or by instructed per sonnel under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations Important functional components in the compressor unit such as the nonreturn valve and safety valve are se
11. compressor unit performance can be determined by measuring the charging time of the air receiver Shut down the compressor unit see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start Isolate the compressor from the air main close the user s shut off valve GG Vent the air receiver with the condensate drain cock and then close the cock again see chapter 9 4 Close the shut off valve on the air receiver gt Start the compressor unit see chapter 8 1 and simultaneously measure and compare the charging time taken to achieve the gauge pressure stated in the technical specifi cation see chapter 1 10 9 35 KAESER COMPRESSORS Maintenance 943 Maintenance Record oae aub RA ER UM Aides Aves RAN Serlal number ceto BO ae tal ene shoe Date Description of work Operating hours Signature KAESER RS COMPRESSO 10 2 Spare Parts and After Sales Service Spare Parts and After Sales Service Service Parts and Expendable Parts Arie 60173 KAESER KOMPRESSOREN GmbH KAE s Carl Kaeser Str 26 96450 Coburg KOMPRESSOREN GERMANY Telefon 49 95 61 64 00 Fax 49 95 61 01 30 Serial NO u Ll eo ecg eel ee Year of production Max working pre
12. f r Schalter R2D2 R2D2 7 neue Version ab Mai 2003 Not Aus Schalter R2D2 R2D2 7 Version ab 2003 50 20 23 02 N Leuchtdrucktaster R2D2 R2D2 7 neue Version ab Mai 2003 50 20 20 04 Stern Dreieck Schalter R2D2 1 1814 00100 Kompressor kompl KC350 40D R2D2 f r USA 1 5732 70190 Kompressor Komplett ECO 3 40D station r 400 V 50 HZ Contec Ausf hrung 1 5737 40220 Kompressor Komplett ECO 4 D R2D2 13 10 04 04 Radachse f r Filterkammer Fahrwerk R2D2 13 10 05 00 Staubbeh lter 90 Liter R2D2 13 10 05 02 Unterlage Gegenhalter R2D2 Pleuel Alu f r ECO 3 2 Kompressor R2D2 Tornado Entl ftungsstopfen ECO 3 2 Kompressor R2D2 und Tornado Zungenventil f r ECO 2 3 Kompressor R2D2 Tornado Kurbelflansch Hub 42 f r ECO 3 2 Kompressor R2D2 und Tornado Winkelverschraubung an der Verbindung Kupferleitung Druckschlauch ECO 3 R2D2 Luftrohr aus Kupfer ECO 3 R2D2 Luftfilternaube Kompressor R2D2 Luftrohr ECO 4 R2D2 Kolben d 70 mm f r ECO 4 Kompressor 2 Kolben d 50 mm f r ECO 3 Kompressor R2D2 Zungenventil f r ECO 4 Kompressor R2D2 Dichtung ZylinderfuB f r ECO S ECO 2 R2D2 Tornado Pa schraube im Kurbelflansch M12x1x33 5 f r Kompressor ECO 3 2 R2D2 und Tornado Dichtung ZylinderfuB ECO 4 R2D2 O Ring FPM 80Sh A 58 0x2 00 f r ECO 2 Zylinderkopf R2D2 und Tornado O Ring FPM 80Sh A 46 0x2
13. for the fan Check decoke or renew valve plate gt k 1 and 2 The motor overload protection triggers after a short period Possible cause Power supply fault 2 phase running Defective motor Remedy Check the power supply fuses 1 Change the motor 1 und 2 The motor overload protection triggers after a long period Possible cause Setting too low Current too high because of low supply voltage Remedy Check the setting see chapter 7 3 1 Check the cross section of power supply cable see chapter 6 4 1 Check the power supply terminals tighten the screws KAESER COMPRESSORS 8 2 6 8 2 7 8 2 8 8 2 9 8 2 10 8 2 11 Operation Compressor runs continuously discharge pressure not reached Possible cause Air filter clogged Valve plate leaking coked or valve reeds broken Pressure losses within the unit Air demand higher than the capacity ofthe compressor Losses at the consumer in the air main Compressor cutting in too often Possible cause Air receiver filled with condensate up to the discharge cock Remedy Clean or renew the air filter see chapter 9 6 1 Check decoke or renew valve plate lt gt 1 and lt 2 Brush soapy water on piping and fittings seal leaks renew leaking parts gt 1 Extend the compressed air supply Check for possible leakage points Remedy Drain the condensate observe environmen tal
14. off and depressurize all pressurized components and enclos ures 2 Secure them in the depressurized state 3 Check that they are indeed de pressurized Attention Any alterations or reconstruction carried out without consultation with and the previous consent of KAESER COMPRESSORS will invalidate the warranty Attention No welding heat treatment or mechanical work may be carried out on pressure retaining conponents e g pipes air mains receivers etc A Safety devices may not be modified or deactivated Signs and marks of reference may not be removed or rendered un readable We also recommend observation of the following e Allow no open flame and flying sparks in the place of installation e During any necessary welding on the compressor unit or nearby ensure that sparks or high temperatures cannot cause fire or explosion e Ensure that the compressor unit is supplied with clean air free of damaging compo nents e The ambient temperature should not rise above or fall below the limits defined in chapter 1 8 If this is the case special measures must be agreed between the manu facturer and the user KAESER COMPRESSORS Safety e 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 These are for example the requirements for specified use in hazardous explosive environments according to the 9
15. oil drain plug back into the crankcase Attention When topping up the oil always use a strainer or pour the oil directly from the new oil can gt Fil up with new oil see chapter 9 3 Clean or Renew the Air Filter The filter cartridge 3 of the air filter 1 consists of oil wetted knitted coconut fibre Clean the filter cartridge 3 at the latest after 500 service hours If the cartridge is heavily contaminated or has been cleaned often renew the air filter complete 1 Air filter 2 Air inlet 3 Filter cartridge 4 Spring clips Shut down the compressor see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start GG Unscrew the air filter 1 from the cylinder head gt Unhook the spring clips 4 and open the filter cap Attention Clean the filter with diesel fuel in the open air Observe the regulations concerning the handling of combustible fluids 9 31 9 7 KAESER COMPRESSORS Maintenance rr Clean the filter cap especially the sealing surfaces gt Wash out the filter cartridge 3 with diesel fuel or clean with a steam jet GG When the filter cartridge 3 is dry wet lightly with oil Attention When screwing on the air filter take care that the air inlet in the filter cap 2 is facing downwards r Screw on the air filter 1 fit th
16. position Attention If the compressor unit does not immediately start wait until the drive motor has cooled down If the motor overload protection triggers several times in sequence other causes maybe responsible for triggering the overload protection e g low insulation of the motor windings or cables seized motor If this occurs have a specialist check the compressor and motor to find the cause of the problem 1 Cover 4 ON OFF switch 2 Dial 5 Screw 3 Mark If necessary adjust the motor overload protection trigger setting as follows Shut down the compressor KAESER A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start gt Loosen the screws 5 to the right and left of the cover 1 gt Remove the cover 1 of the pressure switch Turn the dial 2 with a screwdriver so that the mark coincides with the value of the rated motor current on the dial 2 A Replace the cover 1 after every adjustment of the pressure switch and before starting the compressor unit Replace the cover 1 7 4 Setting up the Pressure Switch A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug see chapter 2 3 to prevent an accidental compressor start before any adjustments are carried out to the compressor unit See chapter 1 6 for t
17. that all maintenance personnel are clear of the machine that all panels are replaced and all access doors closed A The following points must be observed when handling lubricating and cooling materials Avoid contact with skin and eyes Do not inhale vapours 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 replacement parts accumulating during operation and servicing of the compressor package are disposed of according to environmental regulations 9 27 KAESER 9 2 COMPRESSORS Maintenance Regular Maintenance Work Daily Check the crankcase oil level Drain condensate from the air receiver 50 h after initial Check all electrical terminals and tighten if 7 1 start up necessary Change the compressor oil Every 500 h Check and clean the air filter At least once a year Check and clean the check valve Check the pressure relief valve Every 3 000 h Check correct function of the cylinder head and valves Every 10 000 h Change the motor bearings Carry out a general compressor overhaul Maintenance interval may change depending on model installation motor starting frequency and ambient conditions Every 1000 h Change the compressor oil 9 5 at least every 2 years It is recommended that a log is kept of maintenance work done See chapter 9 13 for a sample list of maintenance tasks
18. 0 87 Riemen R2D2 US Version Tornado 70 24 11 62 Riemen R2D2 P 90 24 20 12 38 Taperbuchse f r Riemenscheibe R2D2 P Riemenscheibe Motor R2D2 US Version Riemenscheibe Motor R2D2 Tornado Motor Antrieb Ventilator 5 5 KW R2D2 P Aufbausteckdose 32 A 5P 380 V R2D2 P Aufbaustecker Wendestecker 32 A 5P 380V R2D2 P Steuerleitung f Ventile 3m R2D2 P Harting T llengeh use Kraftstation am Kabel f r Buchseneinsatz R2D2 R2D2 7 Harting Buchseneinsatz Kraftstation im T llengeh use R2D2 R2D2 7 Schnellkupplung aus Messing R2D2 NW 13 Kuplungsdose Druckluftschlauch 3m R2D2 P Schlauchnippel mit Au engewinde 1 2 R2D2 Tornado Seite 1 von 4 90 26 52 11 R2D2 St ckliste Parts List Schlauchnippel mit Au engewinde R2D2 3 8 13 10 03 01 R2D2 F 13 10 03 10 Druckrohr mit Ventilrohren R2D2 F 13 10 03 09 Deckelblech R2D2 Filterkammer Abreinigungsventil R2D2 Tornado Klemmkasten f r Ventilsteuerung R2D2 R2D2 7 KL 1514 Verbindungsschlauch DN 150 mit Kunststof spirale 3 Meter R2D2 Schnellkupplung Stecker aus Messing R2D2 mit 1 2 Gewinde Harting Anbaugeh use an der Filterkammer R2D2 R2D2 7 50 20 20 131 Stifteinsatz der im Anbaugeh use R2D2 R2D2 7 90 20 40 40 Patronenfilter R2D2 Tornado 13 10 05 05 Staubb
19. 00 f r ECO 2 Zylinderkopf R2D2 und Tornado O Ring FPM 80Sh A 46 0x2 00 f r ECO 3 2 Zylinderkopf R2D2 und Tornado Dichtring Zylinderkopf unten ECO 4 R2D2 Dichtring Zylinderkopf oben ECO 4 R2D2 Schildtr ger 111 START R2D2 R2D2 7 Kompressor Luftfiltergeh use ECO 4 5 mit Filter R2D2 R2D2 7 Luftfiltereinsatz ECOS ECO2 Kompressor R2D2 und Tornado 0256 00010 Winkelverschraubung am Zylinderkopf ECO3 R2D2 und ECO 2 Tornado 6 0356 0 Dichtkonus Schneidring f r Winkel verschraubung ECO 3 R2D2 6 0376 0 Uberwurfmutter f r Dichtkonus ECO 3 R2D2 Seite 3 von 4 R2D2 St ckliste Parts List Unterdruckschlauch zum Eimer R2D2 Eimerversion Absaugschlauch DN 125 PU Klar Absaugschlauch DN 125 mit Kunststoff spirale R2D2 Absaugschlauch DN 127 Hoch Temp Absaugschlauch DN 150 PU Klar R2D2 Absaugschlauch DN 150 mit Kunststoff spirale R2D2 Gummipuffer Kompressor Tornado R2D2 Stopfen f r Fahrwerk R2D2 Kompressor ECO 4 5 Manometer an der Entw sserungseinheit R2D2 Schlauchleitung DN 10 x 500 ECO 3 R2D2 Riementrieb Taberlock f r Motorwelle Deltal R2D2 US Riemenscheibe Ventilator R2D2 Tornado Druckregler auf Druckbeh lter R2D2 P Druckrohr zw Kompressor und Druckbe R2D2 ECO 3 Ersatzmembrane 3 4 f r Abreinigungs ventil R2D2 Tornado 90 26 51 17 Schnellkupplung S
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21. 4 9 EU ATEX Directive 2 3 Electrical Safety Attention The electrical system of a compressor unit must comply with the provi sions of the European Standards EN 1012 1 and EN 60204 1 if necessary with the local electricity supply authority regulations Compressor units must be fitted with a main isolating device the oper ation of which determines the start and end of the energy supply Main isolating devices can be main switches or plug and socket con nections For this reason the following measures must be taken at the place of installation Compressor units fitted with a drive motor of drive power 3 kW or more and a current rating of 16 amperes or more must be fitted with a lockable main switch see EN 60204 1 para 5 3 and mains fuses The main switch must be designed according to the maximum rated current In see chapter 1 4 See chapter 1 4 for details of the cable cross sections and mains fuses Compressor units fitted with a drive motor of drive power less than 3 kW and a current rating of less than 16 amperes may be fitted with a mains plug connection 2 4 2 5 KAESER COMPRESSORS Safety Spare Parts Safe and reliable operation of the compressor unit is guaranteed only with KAESER original spare parts Environmental Protection Condensate drainage ba Condensate accumulating during compression must drained a suitable draining system and collected in disposal can
22. 4015 Gunuanay4s Gunuayris sny 4404 u24JMS 93120 40415 4843 0u2S j I 491594409 48j 044u03 Z43nu2s4 dnoH 5 5 484 0u2sz4nu2s40130WN 0008 0460 0708 Sunzyoupus Blatt L al Firma Gelchnungsnumner UNTEC GmbH 57518 Alsdorf zust amp nderung _ gt _ KErs do R2D2 St ckliste Parts List Artikel Nr Part No Bezeichnung 1 Bezeichnung 2 D Nr 13 10 01 00 Maschinenrahmen R2D2 Kraftstation 80 21 31 00 Bockrolle R2D2 80 21 31 60 Lenkrolle R2D2 Tornado 13 10 01 17 Seitenblech links R2D2 P 13 10 01 21 Seitenblech rechts R2D2 P 13 10 01 20 Deckelblech R2D2 P 13 10 01 18 Seitenblech hinten R2D2 P 13 10 01 19 Seitenblech vorne R2D2 P Schaltkasten komplett R2D2 Druckbeh lter 40 Ltr Kompressor R2D2 P Kompressormotor mit Kolbenpumpe ECO 4 R2D2 Kompressormotor mit Kolbenpumpe ECO 4 US Version R2D2 Kompressormotor mit Kolbenpumpe ECO 3 R2D2 niedrige Ausf hrung 0 26 01 43 Wasserabscheider R2D2 Tornado 7 4851 00020 Kompressor Druckschalter ECO 3 40 D und Contec Ausf hrung und ECO 2 7 4851 00030 Kompressor Druckschalter ECO 4 D stat ECO 5 D R2D2 R2D2 7 90 26 00 63 Schalld mpfer R2D2 Tornado Druckstutzen R2D2 P Saugstutzen mit Drosselklappe R2D2 P 90 26 00 60 Ventilator R2D2 P 70 24 1
23. 9 28 KAESER COMPRESSORS Maintenance 9 3 Checking the Oil Level and Topping Up Compressor Block Check the oil level at the oil level sight glass daily and before each start Attention If the oil level has sunk to the lower mark top up the oil immediately according to the oil recommendations see chapter 1 9 Never top up to a level exceeding the maximum oil mark on the oil level sight glass Attention When topping up the oil always use a strainer or pour the oil directly from the new oil can ll 14 min 1 Oil filler with crankcase venting plug 2 Oil level sight glass Shutdown the compressor see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start GG Remove the crankcase venting plug 1 from the oil filler Attention As the oil must flow through the crankcase first the maximum oil level is reached after a few minutes have elapsed gt Fill with oil until the maximum oil level mark is reached See chapter 1 3 for the quan tity of oil required for topping up from the minimum mark to the maximum mark Replace the crankcase venting plug in the oil filler 9 29 KAESER COMPRESSORS Maintenance 9 4 Air Receiver Attention The provisions of the Pressure Vessels Act must be conformed with The relevant
24. Checking Compressor Unit Performance 9 35 9 13 Maintenance 9 36 10 Spare Parts and After Sales Service 10 37 10 1 Service Parts and Expendable Parts 10 37 10 7 a ERR e 11 38 11 1 Electrical 11 38 KAESER COMPRESSORS 1 1 1 2 1 3 1 4 Technical Specification Compressor Unit ee e trt RR RR KC 350 40 D Maximum gauge working pressure 10 Weight har ded 51 Air receiver Capacity kam c uns cnet qa s 40 Max permissible gauge working pressure 11 Drawings Dimensional drawing K1 1814 00030 Electrical diagram SKK D 00400 00 Sound emission Guaranteed sound power level 99 to 2000 14 EG Directive Emission sound pressure level 74 Technical Specification bar kg bar dB A dB A calculated from the measured mean sound power level Directive 2000 14 EG basic standard for noise measurement ISO 3744 to EN ISO 11203 1995 para 6 2 3 d at dis tance d 1m Q2 14 1 dB A Compressor Block ede ibunt Lu er pero KC 350 D Theoretical inlet capacity 350 Free air delivered a
25. care regulations carry out routine main tenance regularly see chapter 9 4 1 Compressor shuts down air escapes constantly at the unloading valve Possible cause Defective nonreturn valve Remedy Renew the seal or renew the valve cone see chapter 9 7 1 Air escapes from the unloading valve when the compressor is running Possible cause Unloading valve not closing dirty or defec tive Remedy Renew the unloading valve see chapter 9 10 1 Unloading valve not unloading after shut down Possible cause Dirty unloading valve Air escapes from the pressure switch Possible cause Defective diaphragm Unloading valve does not close Remedy Renew the unloading valve see chapter 9 10 1 Remedy Renew the pressure switch 1 Renew the unloading valve 1 KAESER COMPRESSORS 8 2 12 8 2 13 8 2 14 Whistling noises at the cylinder head Possible cause Loose cylinder head bolts or defective gas kets Safety valve blowing off prematurely Possible cause Safety valve blows even though the cut out pressure is not yet reached Defective valve spring Safety valve was opened dirt particles stuck in valve seat Oil consumption of compressor too high Possible cause Viscosity of oil too low Defective crankcase venting plug Piston rings worn or damaged Piston rings worn or damaged after only a short period Operation Remedy Tighten th
26. ces must be observed 4 5 Transport Using a Crane A Do not stand underneath hanging loads Do not exceed the max permitted lifting weight of the lifting appliance Always use a sling when transporting the compressor unit with a crane Attention Take care not to damage parts of the compressor when lifting with the sling 4 12 4 6 KAESER COMPRESSORS Transport Storage The machine must be adequately packed GG Store the machine in dry frost free room gt Prevent entry of moisture and condensation If the equipment is to stand idle for a long period the prescribed measures must be taken to avoid damage If any measures can not be taken advice should be sought from the authorised KAESER Service 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 be taken Storage for longer than 6 months Ensure the machine is dry and cover in plastic sheeting Protect the interior with sufficient quantities of desiccant silica gel or similar Storage for longer than 12 months Carry out the following additional maintenance tasks before putting into operation gt In oil lubricated machines the oil and where present the oil filter must be changed GG have the motor bearings checked by an authorise
27. clothing Flapping sleeves may be pulled into the machine causing serious injury 3 rotating parts of the machine are suitably protected by covers which prevent clothes or similar from entering the machine Under no circumstances should these covers be removed before the machine is switched on 4 The R2D2 should be switched off immediately if any unusual noises or vibrations are detected whilst the machinery is in operation A thorough check must be carried out in order to detect the cause 5 Before leaving the R2D2 the operator must switch off the machine and make sure that it cannot accidentally roll from it s position Also disconnect the machine from the mains 6 Check the power cables regularly as damage may have occurred while operating the machine Always disconnect the cables before examination and treat all electrical parts with extreme care 7 Always re connect all the safety plates and covers after any maintenance work 8 If the noise of the R2D2 exceeds 90 dB A ear protections have to be worn by the operator 9 The compressor on the power unit is heating up during operation Don t touch any part of the compressor Danger of burning yourself CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instruction manual R2D2 8 T C 6 Operation Important Before attempting to operate the R2D2 ensure t
28. d KAESER service technician Storage for longer than 3 years after 3 years at the latest the complete technical condition of the machine must be checked before start up Damage to the machine can occur if the condition is not checked CAUTION the the start up carried out by an authorised KAESER service technician 4 13 5 1 5 2 5 3 KAESER COMPRESSORS Construction and Operation Construction and Operation Items in refer to components with item number in the schematic diagram of the com pressor unit see chapter 5 4 Principle of Compression This reciprocating compressor is an air cooled oil lubricated compressor using the prin ciple of single stage compression Atmospheric air is drawn into the compression chamber of the compressor block 2 through the air filter 1 Air is drawn in via the valve plate in the cylinder head during the downward motion of the piston from the top to the bottom dead centres After the piston has reached the bottom dead centre position the air is compressed 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 compressed air now enters the air receiver 4 via a nonreturn valve 3 The nonreturn valve prevents the compressed air from flowing back into the compressor block when the compressor unit is stopped Short Description The compressor block is driven by an
29. e bolts or renew the gaskets 1 and 2 Remedy Check that the pressure gauge functions correctly replace if necessary Check the pressure setting Renew the safety valve 1 Open the safety valve completely for a short period to allow it to blow itself clean Remedy Fill with correct oil see chapter 1 9 X 1 Clean or renew the crankcase venting plug piston rings cylinder gt 2 Renew piston rings and cylinder X 2 ensure that the inlet air is clean e g by using an air filter with a higher grade of fil tration KAESER COMPRESSORS Maintenance 9 Maintenance 9 1 Observe the following during all maintenance and servicing A Disregarding these notes and or improper handling may result in seri ous injury Work on power driven equipment may only be carried out or super vised by persons trained in that particular equipment or by a special ist Work on electrical equipment in the machine may only be carried out according to electrical engineering regulations by a qualified electri cian or trained personnel under the supervision of a qualified electri cian Before starting any maintenance work switch off at the main switch and lock off to secure against unwanted or accidental switching on Make sure the machine is shut off or isolated from the air main during maintenance work to ensure that no compressed air flows back from the main Before switching on again ensure
30. e cap Attention If the cartridge is heavily contaminated or has been cleaned often renew the air filter complete Clean or Renew the Nonreturn Valve The nonreturn valve is fitted to the inlet port of the compressed air line on the air receiver It prevents the compressed air flowing back from the air receiver into the compressor block Check and if necessary clean the nonreturn valve every 500 service hours 1 Nonreturn valve 4 Valve seat 2 End plug 5 Spring 3 Valve cone 6 Sealing ring Shutdown the compressor see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start GG Isolate the compressor unit from the air main close the user s shut off valve GG Vent the air receiver with the condensate drain cock see chapter 9 4 A Do not open the end plug in the valve housing until the pressure gauge indicates zero gt Unscrew the end plug 2 in the valve housing Clean the valve cone 3 and valve seat 4 gt Renew the valve cone 3 the spring 5 and the sealing ring 6 if they are heavily worn or damaged re Reassemble in the reverse order 9 32 KAESER COMPRESSORS Maintenance 9 8 9 9 Checking the Safety Valve If the maximum permissible gauge working pressure in the air receiver is exceeded the safety valve 2 opens and blows off the excess air t
31. e compressor for a short period If the direction of rotation does not coincide with the arrow located on the fan guard change over terminals L1 and L2 7 19 KAESER COMPRESSORS Initial Start 7 3 Setting up the Overload Protection Trigger A Before any adjustments are carried out to the compressor package break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start Attention Three phase motors may be only be run with a correctly adjusted overload protection trigger The motor overload protection trigger is set at the factory with the standard setting Compressor drive motor direct on line start The compressor unit starts directly on line and is controlled by a pressure switch combina tion The pressure switch switches the compressor unit on and off within preset pressure limits and the integral thermal overload protection trigger ensures that the compressor unit is shut down if the current flowing exceeds the preset value Setting rated motor current see motor nameplate The setting can be up to 1096 higher than the rated motor current to prevent voltage fluctu ations triggering the overload protection trigger If the thermal overload protection has triggered and shut down the compressor unit the ON OFF switch switches to the OFF position Start the compressor unit again by setting the switch to the AUTO
32. eh ltergriff mit Griffgummi R2D2 90 20 45 40 VerschluBspanner R2D2 R2D2 7 90 20 45 41 Gegenhalter 6847G 3 f r R2D2 R2D2 7 13 10 05 01 Staubbeh lter 90 Liter R2D2 Laserteil 13 10 05 03 Radachse f r Staubbeh lter R2D2 80 20 32 60 Rad f r Staubbeh lter R2D2 13 10 04 00 Fahrwerk R2D2 80 20 31 60 Hinterrad R2D2 R2D2 7 13 10 08 00 Verbindungsst ck R2D2 f r 90 Liter Beh lter Filterkammer Kraftstation VerschluBstopfen Kappe 125 mm R2D2 F Stopfen Kappe Anschlu rohr 70 mm R2D2 13 10 08 01 Verbindungsst ck R2D2 f r 160 Liter Beh lter Filterkammer Kraftstation 13 10 06 00 Staubbeh lter 160 Liter 2 13 10 06 07 H henadapter f Staubbeh lter 160 Liter R2D2 Steuereinheit Ventile ET Version R2D2 vor Juli 2004 Schaltkasten nur Box R2D2 Transformator f r 4 Pin R2D2 Phasenfolgerelais R2D2 Tornado Motorschutzschalter R2D2 5 5 KW 400 V Hilfsbaustein f r Hauptsch tz oben R2D2 Hauptsch tz R2D2 R2D2 7 Sicherung Ventilsteuerung C6 R2D2 R2D2 7 Sicherung Steuerung C2 R2D2 R2D2 7 Kontaktelement ffner R2D2 R2D2 7 neue Version ab Mai 2003 Kontaktelement K10 R2D2 R2D2 7 neue Version ab Mai 2003 Seite 2 von 4 50 20 33 061 R2D2 St ckliste Parts List LED Element R2D2 R2D2 7 neue Version ab 2003 Befestigungsadapter
33. electric motor 7 The compressor block is directly coupled to the motor via the motor shaft The end of the motor shaft is designed as a crankshaft A fan supplying the necessary cooling air for the motor and the compressor block is fitted to the N end of the motor shaft The heat generated is dissipated via the cooling fins on the cylinder and the cylinder head The crankshaft is supported by roller bearings the connecting rod is supported by shell bearings The cylinder liner piston crankshaft and connecting rod are automatically splash lubricated To enable an unloaded start the pressure switch 6 is fitted with an unloading valve A nonreturn valve 3 is fitted upstream of the air receiver 4 to prevent compressed air flowing back from the air receiver The air receiver 4 is constructed to the regulations of the pressure vessels act and fitted with all necessary fittings such as safety valve 5 pressure gauge 8 pressure switch 6 and nonreturn valve 3 Compressor Control Stop Start Control The compressor is controlled by the pressure switch After the compressor is first switched on the pressure switch switches the compressor de pending on the air demand between the two operating states load and standstill within the limits Pmax See chapter 1 6 for the works setting of the pressure switch The compressed air pipe from the compressor block up to the nonreturn valve is vented when the cut out
34. eneral safety and accident prevention regulations as well as the those laid down in this service manual Attention This symbol is placed by text where considerable attention must be paid to recommendations regulations references and the correct se quence of work so that damage and or destruction of the compressor unit and or other equipment is prevented This symbol identifies environmental care measures This symbol indicates operations and actions to be carried out by the operator or service technician e This bullet identifies listings Explanation of the warning label on the compressor unit N Warning Do not touch hot surfaces KAESER COMPRESSORS Safety 2 2 Safety Notes A Work on power driven equipment may only be carried out super vised by persons trained in that particular equipment or by a special ist Work on electrical equipment in the compressor may only be carried out according to electrical engineering regulations by a qualified elec trician or trained personnel under the supervision of a qualified elec trician A Before work is carried out on electrical systems carry out the follow ing measures in the sequence shown Switch off all phases Ensure the unit cannot be switched on again Check that no voltage is present A The following actions must be carried out in the order given before working on any pressurised parts or enclosures e g pipes vessels valves 1 Shut
35. er completely or partly distributed or evaluated by unauthorised persons for the pur pose of competition or divulged to any other third party KAESER COMPRESSORS General 3 5 3 6 Accompanying Documents With this Service Manual are documents intended to assist in safe and sure operation of the compressor e Certificate of acceptance operating instructions for the pressure vessel e Conformity or Manufacturer s Declaration in accordance with applicable directives Make sure all documents are to hand and their contents understood Request the supply of any missing documents from KAESER Make sure you give the data from the nameplate Handling the Document The service manual is part of the machine gt Keep the service manual safe throughout the life of the machine gt Pass the manual on the the next owner user of the machine Ensure that all amendments are entered in the manual 3 10 KAESER COMPRESSORS Transport 4 1 4 2 Transport and Storage Take the machine out of service The machine must be correctly taken out of service in preparation for transport for trans port t Switch the machine 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 GG Switch off and lock out the main switch gt Wait at least five minutes before checking
36. ervice when the above maintenance is due 9 33 KAESER COMPRESSORS 9 10 Maintenance Renewing the Unloading Valve of the Pressure Switch If a dirty unloading valve causes the compressor unit to start with difficulty it must be re newed 1 y 2 1 Unloading valve 2 Hex socket head bolt Shut down the compressor unit see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start Isolate the compressor unit from the air main close the user s shut off valve Vent the air receiver with the condensate drain valve see chapter 9 4 Unscrew the hoses from the pressure switch Unscrew the hex socket head bolt 2 and take out the unloading valve 1 Fit a new unloading valve Start the compressor unit see chapter 8 1 4 y y Check for leaks e g brush on soapy water Check or Renew the Cylinder Head and Valves Compressor Block Check the cylinder head and the valves for correct function after 3000 service hours Attention If faults are obvious on the cylinder head or the valves these parts must be repaired or renewed by KAESER Service Have the compressor generally overhauled by KAESER Service after 10000 service hours 9 34 KAESER COMPRESSORS Maintenance 9 12 Checking Compressor Unit Performance The effective
37. fference between the in and cut out pressures gt the screw 4 counterclockwise direction Cut in frequency of the compressor unit from standstill to load The cut in frequency of the compressor unit from standstill to load can be changed within a limited range by changing the switching difference To change the cut in fre quency the pressure switch must be adjusted see chapter 7 4 Attention See chapter 1 5 for the maximum cut in frequency from standstill to load per hour e Increasing the switching difference causes a decrease in the cut in frequency e Decreasing the switching difference causes an increase in the cut in frequency KAESER COMPRESSORS Operation 8 1 8 2 8 2 1 Operation Starting and Stopping the Compressor Unit Starting the compressor unit t Operate the main isolating device main switch or plug see chapter 2 3 1 ON OFF switch 0 position OFF position AUTO GG Switch on the compressor unit at the pressure switch turn switch to position Shutting down the compressor unit GG Switch off the compressor unit at the pressure switch turn switch to position 0 rz Operate and lock out the main isolating device to isolate the compressor from the mains power supply Faults and their Removal A Always comply with all general and local safety regulations when carrying out faultfinding and repair
38. for electrical voltage GG Work carefully t Isolate the machine from the air main by closing the user s compressed air inlet outlet shut off valves Initial and final pressure gauges must read zero Allow the machine to cool down completely gt Ifthe machine is water cooled shut off the water supply drain the water completely from the heat exchanger and dispose of it according to environmental regulations GG Disconnect all supply lines Packaging Always 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 by the customer Overland The machine should be protected from mechanical damage by a sturdy crate and from moisture by plastic sheeting By sea or air Special packaging instructions can be obtained from KAESER ba Dispose of the packaging according to environmental regulations and recycle where possible 4 11 KAESER COMPRESSORS Transport 4 3 Transport Instructions A 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 truck In order to move the machine by means of a fork or pallet truck it must be on a suitable pallet or transport frame o9 Attention If the compressor unit is transported by a crane the safety regulations concerning lifting applian
39. gauge pressure is reached to ensure an unloaded compressor start 5 14 KAESER COMPRESSORS Construction and Operation 5 4 Components of the Compressor Unit 2 11 9 10 1 7 14 35 6 8 4 12 13 Lt EB 1 Air filter 8 Pressure gauge cleans indicates the current pressure the inlet air in the air receiver 2 Compressor block 9 Oil level sight glass draws in the air and compresses it to the discharge pressure 3 Nonreturn valve 10 filler with crankcase venting prevents the compressed air from plug flowing back into the block 4 Air receiver 11 Oil drain plug compressed air tank and accumulation of condensate 5 Safety valve 12 Compressed air discharge connection protects the air receiver blows off to the air mains if the max working pressure is exceeded 6 Pressure switch 13 Condensate drain cock controls compressor stop and start 7 Electric motor 14 Direction arrow on the fan guard drives the compressor block Fan on N shaft end provides the necessary cooling air 5 15 KAESER 6 Installation 6 1 Installation Instructions To ensure sufficient ventilation the compressor unit must be installed with a minimum dis tance of 0 5 metres to the wall Safe operation of the compressor unit is only ensured if the ambient temperature remains within the limits stated in chapter 1 8 Ifthe compressor is used in the open take care that it is protected against the direct rays ofthe sun and agains
40. hat you are fully familiar with all the controls and the safety regulations of this manual Connect the R2D2 dust collector via the dust hose to the application for example shotblaster floor grinder or floor planer Make sure that the dust hose is in good condition and without any tears or other defects Little holes can dramatically reduce the performance of the dust collector Check the electric cables Connect the extension lead to the mains and to the socket on the power unit picture 11 You need a 460 V 3 phase power supply It 1s possible to make one unit out of the power and filter unit On one side of the filter unit are two clamps in rectangular pipes Pull them out and turn them 90 Slide the end of the clamps inside two holes on the side of the power unit Now the two units are one machine which can be moved as one on site Connect the 150 mm diameter hose from the power unit to the filter unit Connect the air pressure hose and the electric connection of the power unit to the filter unit Press the START button on the control panel If the indicator light on it s right side doesn t stay on when you release your finger then the motor wants to start in the wrong direction In this case disconnect the plug picture 10 on the power unit The plug is a reverse plug which means that two phases can be swopped by inserting a screw driver in between the pins and twisting them round to the opposite direction This allows the
41. he factory setting of the pressure switch and the pressure diagram Attention The pressure setting can only be changed with the pressure switch fitted and under pressure Attention Do not set the maximum cut out pressure higher than the maximum gauge working pressure see chapter 1 1 o Cover Screw Upper switching point Cut out pressure adjusting screw Pressure difference adjusting screw ON OFF Switch OFF AUTO Shut down the compressor unit see chapter 8 1 Q N A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start KAESER COMPRESSORS Initial Start 7 4 1 Unscrew the screws 2 to the right and left of the cover 1 gt Remove the cover 1 of the pressure switch GG Carry out the adjustment of the pressure switch A Replace the cover 1 after every adjustment of the pressure switch and before starting the compressor unit gt Replace the cover 1 To increase the cut out pressure gt the screw 3 clockwise in the direction To decrease the cut out pressure gt Turn the screw 3 counterclockwise in the direction To increase the pressure difference between the cut and cut out pressures the screw 4 clockwise in the direction To decrease the pressure di
42. he following pages you will find all the necessary information to achieve a safe reliable and highly competent performance from the R2D2 It is therefore important to follow the strict guidelines for the deployment and servicing of the R2D2 in order to obtain optimum performance It is in the interest of all persons operating or using the machine to take note of the operating instructions in this manual in order to be fully conversant with the components and functions of the R2D2 dust collector 2 Machine applications Collecting of dry dust produced by CONTEC Surface Preparation Machines The use of the machine outside is only possible in dry weather CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instruction manual R2D2 T C Declaration of Conformity according to EN ISO IEC 17050 1 EC Declaration of Conformity Month Year For the machine described below Product denomination Dust Collector Model R2D2 Serial number Herewith we declare that the machine is complying with all the essential requirements of the Machine Directive 2006 42 EC of the EUROPEAN PARLIAMENT of the 17th of Mai 2006 The person authorized to compile the relevant technical documentation According to Appendix Nr 1 A Nr 2 2006 42 EG Name Surname Greb Johannes Function Technical Ma
43. isters The con densate must be disposed of according to environmental regulations Operational and repair materials used parts Dispose of all used materials and parts accumulating during oper ation maintenance and repair of the compressor unit according to environmental care regulations Disposing of the Machine When disposing of a machine drain out all liquids and remove dirty filters Any parts contaminated with oil must be disposed of accordance with local environment regulations the machine out of service see chapter 8 1 gt 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 correct disposal of the empty machine KAESER COMPRESSORS General 3 3 1 3 2 3 3 3 4 General Attention The service manual must always be available at the compressor unit s place of use Correct Use of the Compressor The compressor unit is intended solely for the purpose of generating compressed air Any other use is considered incorrect The manufacturer cannot accept liability for any damage caused by such incorrect use the user alone is liable for any risks incurred Correct use of the compressor also encompasses compliance with the installation re moval commissioning operational and maintenance conditions laid down by the manufac turer Attention The e
44. motor to run in the correct direction When there is no pressure in the air tank the compressor starts to work Turn the star delta switch in the star position The motor begins to turn Wait approximately 10 seconds before you turn the switch into the delta position It is important to wait long enough before you switch over from the star to the delta position Wait until the motor is not increasing the speed any more before you switch over You can now start to work The dust bin of the R2D2 has to be emptied during operation How often depends on the amount of dust produced during the application Only dry dust or dry material can be removed by the R2D2 Wet or greasy dust blocks or in the worst case destroys the filter cartridges CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instruction manual R2D2 9 T C 6 1 Variations of the dust collection Basically there are two methods of collecting the dust with the R2D2 first one simply fills the dust container picture 8 with dust which can then be emptied The second method fills a bag within a bin picture 7 When the bag is full it can be sealed with a string and then disposed of into a container Method one reduces waste in the form of plastic bags method two reduces the possibility of problematic dust escaping into the air 6 1 1 Ope
45. n to the power supply and the protective measures necessary are to be carried out to the provisions of the European Stan dards 1012 1 and EN 60204 1 and to the regulations of the local Electricity Supply Authority by an authorised electrician Attention For this reason the following measures must be carried out at the place of installation Compressor units fitted with a drive motor of drive power 3 kW or more and a current rating of 16 amperes or more must be fitted with a lockable main switch see EN 60204 1 para 5 3 and mains fuses Compressor units must be fitted with a main isolating device the oper ation of which determines the start and end of the energy supply Main isolating devices can be main switches or plug and socket con nections The main switch must be designed to according to the maximum rated current IN see chapter 1 4 Compressor units fitted with a drive motor of drive power less than 3 kW and a current rating of less than 16 amperes may be fitted with a mains plug connection e The electrical installation of the compressor unit must be carried out according to the electrical diagram see chapter 11 1 The connection to the power supply is made with a mains plug Attention The supply cable and fuses are selected to DIN VDE 0100 sect 430 and 523 for an ambient temperature of 30 Under other operating conditions such as a higher ambient temperature or longer supply cables
46. nager Address Neuer Weg 17 57518 Alsdorf Germany More information on the compliance with the directive is contained in Appendix 1 This Declaration is given by the manufacturer Name Contec Maschinenbau amp Entwicklungstechnik GmbH Address HauptstraBe 146 57518 Alsdorf Deutschland Germany Given by Name Surname Greb Johannes Function Technical Manager Alsdorf 22 12 2010 224 Place Date Signature Appendix 1 of the Declaration of Conformity Month Year For the machine described below Product denomination Dust Collector Model R2D2 Herewith we declare that the machine is complying with all the essential requirements of the Directive 2004 108 EC of the EUROPEAN PARLIAMENT of the 15th of December 2004 on Electromagnetic Compatibility Directive 2006 42 EC of the EUROPEAN PARLIAMENT of the 17th of Mai 2006 Harmonised Standards used EN 12100 1 Safety of Machinery Basic concepts EN 12100 2 Safety of Machinery Technical principles CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instruction manual R2D2 5 T C 4 Description Picture 1 Picture 2 R2D2 Power unit R2D2 Filter unit container version Picture 3 Picture 4 R2D2 Filter unit bag version Compressor Picture 5 Picture 6
47. nd the water inside the tank has to be emptied regularly All necessary information is given in the compressor manual in the appendix 7 3 Water separator Picture 5 shows the water separator of the R2D2 The water separator separates the water from the compressed air and makes sure that no water will be pressed inside the filter cartridges The separator has to be checked on a regular basis and the tank has to be emptied when full The speed with which the tank fills with water depends on the moisture of your location To empty the tank open the valve on the bottom side of the separator 7 4 Filter cartridges If the performance of the R2D2 is not sufficient any more or if the filtration is no longer dust free the filter cartridges have to be checked Before you start the dust collector should be switched on for a while without sucking dust The pulse jet cleaning mechanism then removes most of the dust on and around the cartridges Remove the dust bin picture 7 to 9 If you have a bag version the conical part of the machine frame picture 3 has to be unscrewed By loosening the wing screws underneath the cartridges they can be pulled out of the machine Use air pressure to clean the filters and check them for any damage If necessary one or all the cartridges have to be replaced CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instr
48. o protect the compressor unit and the consumers connected to the air mains To prevent the valve seat from sticking open the safety valve every 500 service hours or at least annually 1 Knurled ring 2 Safety valve Attention It is essential to wear ear protection when testing the pressure relief valve because of the loud noise produced by escaping air GG Switch the compressor off see chapter 8 1 A Isolate from the power supply by means of the main switch or by with drawing the mains plug and lock out the switch to prevent an inadver tent start Turn the knurled screw on the pressure relief valve anticlockwise until air escapes and then turn back again Attention A defective pressure relief valve must be renewed completely Attention Tampering with the pressure relief valve and damaging the lead seal is forbidden and will invalidate all liability Maintenance of the Motor Bearings e The motor bearings are permanently greased e Under normal operating conditions with ambient temperatures around 25 C the motor bearings should be renewed approximately every 10 000 service hours e The wear on the bearings increases with higher ambient temperatures With very high ambient temperatures of around 35 C renew the bearings approximately every 6000 hours e Change the motor bearings every 3 years independent of service hours Attention The bearings must be changed by KAESER S
49. quipment may only be used or serviced by persons who are au thorised and trained The machine is intended solely for industrial use and application in industrial facilities Any other use or application is forbidden The manufacturer is not liable for any damages resul ting from such unspecified use or application The user or operator alone bears the risk for such damages This applies especially to the obligation e to become acquainted with the fundamental safety regulations that apply to compressed air engineering e refuse access to the machine by persons under the age of fourteen and e to have the technical condition of the machine inspected within the intervals prescribed for industrial use Incorrect Use A Never direct compressed air toward persons Compressed air is a con centrated form of energy and as such is dangerous to life Attention Inlet air may not contain any explosive or chemically unstable gas vapour Compressed Air Treatment A Never use compressed air for breathing purposes and production methods where the air has direct contact with food without subjecting the compressed air to additional treatment Copyright The copyright of this service manual is the property of the KAESER Company This service manual is intended for operating personnel maintenance personnel and supervisory per sonnel use only It contains instructions and technical diagrams that may not be copied eith
50. ration with the container version Switch the R2D2 On see chapter 5 Operation The dust container picture 8 is located underneath the filter cartridges During operation the dust container will fill up For emptying the container switch the R2D2 There for clamps picture 14 which keep the container underneath the filter unit Open the clamps and the container will be lowered down to the floor There are two handles on the container which allows you to use the container as a wheel barrow Empty the container Fix the now empty container using the steps shown above in reverse order 6 1 2 Operation with the bag version Remove the bins from the R2D2 dust collector Place the bag in the dust bin as you would with a normal dust bin The opening of the bag must be pulled around the opening of the bin Lift the bin with the handle Connect the vacuum hose The dust bag will be sucked to the inner side of the dust bin This opens the bag and it can be filled with the dust Attention The vacuum hose must be connected correctly when operating with a dust bag If not properly connected the bag will be sucked into the machine Open the dust valves The bag will now be filled during operation When the bag is full remove the vacuum hose The bag will now close around the dust like a bottle neck Close the dust valves Lower the bins to the floor by raising the lift handles If necessary the bottle neck of the bag can be sealed with s
51. regulations of the country concerned must also be ob served Drain the condensate collecting in the air receiver daily with the condensate drain valve 1 ba Drain the condensate into a suitable container and dispose accord ing to environmental care regulations 1 Condensate drain cock 9 5 Oil Change Compressor Block Change the oil with the compressor unit at normal operating temperature A Danger of scalding by hot oil Danger of burns from hot components Change the oil after approximately the first 50 service hours Change the oil futher see chapter 9 2 If under unsuitable operational conditions condensed water is observed in the oil recog nisable by the milky colour in the oil level sight gauge 2 carry out an oil change immedi ately 1 Oil filler 2 Olil level sight glass 3 Oil drain plug 9 30 KAESER COMPRESSORS 9 6 Maintenance Shut down the compressor see chapter 8 1 A Break the power supply by operating and locking out the main isolat ing device main switch or mains plug to prevent an accidental com pressor start gt Remove the crankcase venting plug 1 from the oil filler gt Prepare a container to catch the oil ba Collect the used oil and dispose of according to environmental care regulations gt Unscrew the oil drain plug 3 and drain the oil into the container gt Flush out the crankcase with small quantity of new r Screw the
52. ressor is running 8 25 8 2 10 Unloading valve not unloading after shut down 8 25 8 2 11 Air escapes from the pressure switch 8 25 8 2 12 Whistling noises at the cylinder head 8 26 8 2 13 Safety valve blowing off prematurely 8 26 8 2 14 Oil consumption of compressor too high 8 26 9 Maintenance u eee a 9 27 9 1 Observe the following during all maintenance and servicing 9 27 9 2 Regular Maintenance 1 4 9 28 9 3 Checking the Oil Level and Topping Up Compressor Block 9 29 9 4 But 0 0 ss ond d paha 0 selves pau used ntis 9 30 9 5 Oil Change Compressor 9 30 9 6 Clean or Renew the Air 9 31 9 7 Clean or Renew the Nonreturn Valve 9 32 9 8 Checking the Safety Valve 9 33 9 9 Maintenance of the Motor Bearings 9 33 9 10 Renewing the Unloading Valve of the Pressure Switch 9 34 9 11 Check or Renew the Cylinder Head and Valves Compressor Block 9 34 9 12
53. ss g Free air delivered Rated voltage Rated motor speed Rated power Ambient temperature Ordering Spare Parts When ordering spare parts always state see nameplate Compressor model Year of manufacture Part number Serial number Important for all queries Enter the data from the nameplate of the compressor unit in the nameplate illustrated above Always quote the data on the nameplate when ordering spare parts or making enquiries Attention Do not fit inferior consumable or spare parts Use only original parts supplied by the compressor manufacturer We must point out that maintenance parts spare parts and accessories not delivered by KAESER are also not tested and cleared by us The fitting and or use of such products can under certain circumstances change the design characteristics of the compressor unit negatively and therefore affect the active and or passive safety of the unit The use of such parts or accessories exempts KAESER from all liabilities and warranties for consequential damage caused by such parts or accessories 10 37 KAESER COMPRESSORS Appendix 11 Appendix 11 1 Electrical Diagram see following page 11 38 m 76 5 2 Jojow Jossa dwo aseyd aauy 5 7 jiun 40ssa duio3 N3U0SS RAA 81539 3 sewapwe
54. t 6 bar gauge working pressure 230 Maximum gauge working pressure 10 Number of cylinders 1 1800 2 0 2 Oil top up quantity 0 1 Electrical Connection Mains voltage 460 10 Ph ses P 3 N PE Frequency i n a ae ate es 60 Max mains fusing slowblow gl class 6 Power supply cable core cross section 4x1 5 CU multiple core cable Maximum rated current Ip 3 5 l min l min bar min KAESER 1 5 1 6 1 7 1 8 1 9 Drive Motor Rated power 1 7 kW Fated Speed auri uama pakan ede alee adus 1800 min Protection class IP 54 cut in frequency 30 times hour eese direct start Air Main Pressure Switch Setting 5 x MDR 3 11 8 Possible adjustment range a 7 of the air main pressure switch ke 6 0 5 lt 4 4 9 5 2 1 0 01234567891011 Cut out pressure bar Works settings Gauge cut iin pressure Pmin 7 bar Gauge cut out pressure 9 bar Pressure difference Ap
55. t the ingress of dust and rain 6 2 Connection of the Compressed Air Supply The compressor unit is piped ready for use KGB006011 1 Compressed air discharge connection A compressed air connection is provided for the consumers The consumers are con nected via a flexible hose and a quick release hose coupling 6 16 KAESER 6 3 Fitting the Antivibration Mounts The antivibration mounts supplied with the compressor unit as a separate package fixed to the compressor block must be fitted before the compressor is first put into operation Attention Use transporting belts to lift the compressor unit Observe the instruc tions in chapter 4 5 A The compressor can tip because of its own weight and high point of gravity Attention The antivibration pads must be fitted according to the arrangement shown in the following diagram 1 Antivibration mount 2 Antivibration mount soft 40 Sh 4 1493 0 hard 90 Sh 4 1476 0 1 Antivibration mount 4 Washer 2 Fastening bolts 5 Spring washer 3 Wooden base 6 Hexagonal nut GG Lift up the compressor unit with the transport belt Observe the instructions in chapter 4 5 Unscrew the bolts 4 and remove the wooden base 3 from the feet of the air receiver gt Fit the antivibration mounts 1 with washers 4 spring washer 5 and hexagonal bolt to the feet of the air receiver 6 17 KAESER 6 4 Electrical Connection A The connectio
56. t up and fitted at the factory to precise setting up regulations Changes are not permitted without previous consultation with KAESER The nonreturn valve and the safety valve are spring loaded Points to be observed before starting the compressor unit A ANY NON OBSERVANCE OF THESE OR OTHER REFERENCES WARNING ATTENTION CAN LEAD TO ACCIDENTS CAUSING IN JURY TO PERSONNEL OR DAMAGE TO EQUIPMENT The machine restarts automatically after a power failure provided the air main pressure is lower than the cut out pressure level set on the air main pressure switch e expected that the operator employs safe working methods and that all valid and if applicabel all local operating and safety regulations are complied with when operating the machine The user of this machine is responsible for its safe operating condition Do not operate this machine in spaces where high dust pollution poisonous or inflam mable vapours or gases could exist e Do not connect the machine to a supply voltage other than that stated on the name plate e Do not install the machine in a space subject to freezing temperatures whereby the air temperature conditions at the compressor s air inlet must be complied with see chapter 1 8 e Check the level of the oil in the compressor block If necessary top up according to the oil recommendations see chapter 1 9 Direction of Rotation Check e Check the direction of rotation by switching on th
57. tecker aus Messing R2D2 mit Schlaucht lle NW 13 90 26 52 12 Doppelnippel mit Au engewinde 1 2 R2D2 Tornado Seite 4 von 4 SERVICE MANUAL _ Reciprocating Compressor Model KC 350 40 D Nr 1 1814 00100 01 01 Part 1 1814 00100 Serial Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com DECLARATION OF CONFORMITY within the meaning of Machinery Directive 98 37 EC Anex II A la 157 elt Specification of machine assembly Description Reciprocating Compressor 00000000 Model KC350 40D Material No 1 1814 00100 1 Serial nn EG directives applied 98 37 CE Machinery directive 73 23 CEE Low Voltage Directive 87 404 CEE Directive concerning simple unfired pressure vessels 89 336 CEE Directive concerning electromagnetic compatibility Harmonised Standards applied DIN EN 1012 1 1996 07 DIN EN 55014 1 2002 09 DIN EN 292 1 1991 11 DIN EN 61000 6 2 2002 08 DIN EN 292 2 A1 1995 06 DIN EN 61000 3 2 2001 12 1 DIN EN 294 1992 08 DIN EN 61000 3 3 2002 05 5 DIN EN 60204 1 1998 11 DIN EN 61000 3 11 2001 04 5 1 Insofar as the application falls within the requirements of the standard The design of the machine supplied by us corresponds to the stated Directives and Standards within the meaning of the conformity assessment procedure carried out
58. tring This minimises the possibility of dust escaping into the air Pull the bins out of the machine and remove the dust bags Take new bags and start from the beginning Attention When the dust bin is removed from the R2D2 and no dust should escape from the machine the dust valve must be closed lever horizontal and the ventilator left running The dust valve is not 100 airtight but because the ventilator runs continuously air is also sucked continuously inside the dust collector This prevents dust escaping out of the valve CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne CONTEC 2012 info contecnorthamerica com www contecnorthamerica com Instruction manual R2D2 10 T C 7 Maintenance 7 1 Belt drive The belt drive picture 12 has to be tensioned periodically Loosen the four screws which fix the motor to two rails Only loosen the screws don t remove them Picture 12 shows a screw in between the ventilator and the motor below the belts Loosen the nut and turn the screw clockwise until the belt has the correct tension The belt shouldn t move more than one centimetre half way in between the pulleys Before tightening the motor foot screws check if the two pulleys of the motor and ventilator are still in line If they are not in line change the position of the motor on the rails until the right position is found 7 2 Compressor The oil level of the compressor has to be checked a
59. uction manual R2D2 8 Technical data 8 1 Power unit 1 86 6 Height in cm 148 58 in Length in cm 101 40 in Width in 51 20 in Weight in kg 160 353 Ibs Electrical connection 460 V 60 Hz 3 Phase 10 2 A Max airflow in m min 38 1 342 cu ft min Max vacuum 10150 Pa 101 5 mbar Filter cleaning system Pulse jet Noise level Lwa 83 dB A Noise level Leq 7 dB A Data VUA Verein zur berwachung technischer Anlagen e V 8 2 Filter unit container version Height in cm 120 47 in Length in cm 105 41 in Width in cm 79 31 in Weight in kg 120 265 Ibs Filter area in m 10 107 sq ft Number of filter cartridges 5 Dust ports in mm 70 125 2 76 4 92 in Volume of dust bin in I 90 24 gal standard 160 42 gal optional 8 3 Filter unit bag version Height in cm 165 65 in Length in cm 105 41 in Width in cm 79 31 in Weight inkg 160 353 Ibs Filter area in m 10 107 sq ft Number of filter cartridges 5 Dust ports in mm 70 125 2 76 4 92 in Volume of dust bin inl 2 x 75 19 8 gal Technical data subject to change 9 Appendix Diagrams Wire diagram Part list Manual Compressor CONTEC GmbH Hauptstrasse 146 57518 Alsdorf Deutschland Germany Allemagne info contecnorthamerica com www contecnorthamerica com CONTEC 2

R2D2 Manual - Runyon Surface Prep Supply

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