SERVICE MANUAL - Sable Industries Inc.
Contents
1. JJapuna Qv anu va OYeqoA vaGunJepuy KAESER KOMPRESSOREN Sound enclosure for K402055_0 10067788 D 01 Ersatz fur koch4 05 10 2005 SRR gt gt SRR RENI RR RRR e Doo RRR SA QS NN coll gt gt A A 54 S hez Freigeg 06 04 2006 uapJa asian JaBisuos Japo uajnp u3ou X387 aJ JDqUIaJaA nz JNU uejJnp 5 Bunpua aA sapun BunjreJqJaA Japo Bunueuareds ualdoy nz OP pun 38 uajJoquiaJa nz JNU ais uinjuefi3 Jesun 7 910 m K1_5203_0 P01 10066309 D 01 KAESER KOMPRESSOREN2. uapJa asian JaBisuos Japo u3ou X387 aJ JUQUia Ja NZ JNU 5 5 Jauasiuo4 ena Japun BunjiaJqJ8A Gunsayziads uarrgjenuasure sapo ualdoy J PU MJ A U J PUD NZ JOP PUN 7 nz JNU als seuprycjaruassnm sasun 91910 7 90 K1_5373_0 10062463 0 01 KAESER KOMPRESSOREN Ersatz fur koch schaefi 23 06 2005 23062005 hez I Ji Cy Jaqn anu jJop Dunutpraz ajfuipagsfunpprequg asia Ja61suos tou uap a pax UAL DqUIaJBA
3. EIS 4 15 4 2 Operating States and Control Modes 4 16 4 2 1 Operating states 4 16 KAESER COMPRESSORS Contents Chapter page 4 3 Compressed Air 4 16 4 3 1 Function diagram n 4 16 4 3 2 Drying the compressed air 4 16 4 3 3 Desiccant regeneration 4 16 4 4 Safety Devices orris e ees eh es eee 4 17 4 5 ACCOSSONGS A Pana Gaul 4 17 4 5 1 Sound enclosure see chapter 6 6 4 17 5 Installation and Operating Conditions 5 18 5 1 SUIMOUNGINGS CPC V RR 5 18 5 2 Installation Conditions 5 18 5 2 1 Place of installation and space required 5 18 5 2 2 MentllatiOri uve ree me lUi e e 5 19 5 2 3 Operating a compressed air system 5 19 6 Installation ioe e rhe I xung 6 20 6 1 oi S EU RAD dU LL DAL AUI EL IE 6 20 6 2 Reporting Transport 6 20 6 3 Installing the Antivibratio
4. Spare Parts for Service and Decommissioning esee Packing sce ER REND Ped Ears Sete een SOLAS desc ae ne eMe cu peperit ris nas Transporting rhe Fue ponerme e Ea xn bre eben eeu rinse uus eX bra Ee xut Diagrams and Drawings Dimensional drawing Electrical Diagram Contents Chapter page KAESER COMPRESSORS Directory of Illustrations Chapter page Fig 1 Location of Safety Signs 3 13 Fig 2 Major components 4 14 Fig 3 Machine Overview 4 15 Fig 4 Installation recommendation 5 18 Fig 5 Antivibration mount Hm 6 21 Fig 6 Compressed air connection 6 21 Fig 7 X Fitting the sound enclosure 6 23 Fig 8 us obese bere ce t dcs x bie 7 25 Fig 9 Switching on and off 8 27 Fig 10 Changing the Filter 10 33 Fig 11 Air filter maintenance 10 34 Fig 12 Checking the safety re
5. 9 30 Tab 16 Regular maintenance tasks 10 32 17 Regular service work eect tenes 10 32 Tab 18 Logged maintenance tasks 10 39 Tab 19 Machine maintenance parts 11 40 Tab 20 Seccomat dryer maintenance parts 11 41 KAESER 1 1 1 2 1 3 1 4 1 4 1 Regarding this Document Handling the Document The service manual is part of the machine r Keep the service manual a safe place throughout the life of the machine Pass the manual on to the next owner user of the machine r Ensure that all amendments received are entered in the manual Ea Enter details from the machine nameplate and individual equipment in the table in chapter 2 Technical Specifications Further Documents Included with this Service Manual are documents intended to assist in the safe operation of the machine e certificate of acceptance operating instructions for the pressure vessel Make sure all documents are complete and observe the instructions contained in them Missing documents can be requested from KAESER Always quote the data on the nameplate Copyright This service manual is copyright protected Please contact KAESER if you have any queries regarding use and copying of the documentation We wi
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7. Ersatz f r koch4 schaef1 12 09 2005 Freigeg 14 09 2005 uapJaA JyIDWAB 2 asia JaBlysuos ur sapo uat uapuam aa nz uaJJnp Jauasiuo J aja Gunpuamsa Bunjraquova Bunvayriads aBljsuos ualdoy UapJaA JapuaAJaA uapJam Jepupab y Jeqn Bunuuptez uar uaqJoA NZ jJDp pun UeJJDQuIa3A nz JNU els sayangyanyassno sasun 441319 BunuysIeZ 210 KAESER COMPRESSORS Appendix 13 1 2 Electrical Diagram 13 55 1092010 msn CETT NC NN 270 Peg pugne 1e4u3q peo abed sanoa 53 rash soar vat sajjJed ajgissazze asiMJayjo Jo papJeMJoj jsnu suoijonpoJdaJ Jou sjeuibiJo JaujieN asodund paaJbe ayy Jaujo Aue Joy apeu aq jou ysnw suiaJs S 31u0J428 a jo asn Aq pue juaujeaJj abeJojs Duipnjour suoijonpo4daJ sayyo Aue Jo saido asodund paaube ayy pajsnJjua ayy jJadod a
8. 2 5 2 9 Machine Duty 2 6 3 Safety and Responsibility 3 7 3 1 Proper Use uci cra Pa eee sehen Fahad eee 3 7 3 2 Improper USE su cocer ee ie ais ee nies ERE RENT aie ee ad 3 7 3 3 User s Responsibilities lesse 3 7 3 3 1 Qualified personnel 3 7 3 3 2 Adherence to inspection schedules and accident prevention regulations 3 8 3 4 3 8 3 4 1 Safely dealing with sources of danger 3 8 3 4 2 Safe machine operation 3 10 3 4 3 Taking organisational measures 3 11 3 4 4 Hazard areas s Bartel odes A 3 11 3 5 Safety DeviCeS lt 4 pa twee Ee RR redii di pads 3 12 3 6 Salety SIGNS oc use VERDE EU 3 12 3 7 Emergency a utah EUER E En EE Mi 3 13 3 7 1 Fire fighting tom BGA ERR eee PERL eeu Y xul RD RA 3 13 3 8 Environmental protection 3 13 3 9 m itl b b e ha tede seth ER he ED UE I ER 3 138 4 Design and Function iius ex SEE Ea oun te ees ts Ros 4 14 4 1 Machine Overview 4 14 4 1 1 Primary components ss ereer iret i a EE 4 14 4 1 2 FUNCTION du
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11. Clean the housing and sealing faces I Replace the filter element 2 if it is badly clogged or has been cleaned often Refitting the air filter gt Insert the dry element 2 in the rubber 3 and replace on the cylinder head I The inlet opening 4 in the filter housing must face downwards t Switch on at the main power supply disconnecting device Electric Motor Maintenance The motor bearings are permanently greased and need no further greasing e 1 o T Under normal operating conditions ambient temperature around 77 F have the motor bearings changed at the latest after 4 000 operating hours Higher wear takes place at at ambient temperatures around 95 F Regardless of operating hours the motor bearings must be changed after 5 years Have the motor bearings changed by an authorized KAESER Service representative 10 34 KAESER COMPRESSORS Maintenance 10 6 Checking the Safety Relief Valve Pre condition Machine switched off under load Power supply disconnecting device locked out To prevent the safety valve from sticking it should be activated at regular intervals or at least once a year AN Excessive noise is caused when the safety relief valve blows off CAUTION Wear ear and eye protection tx Work with caution e T 3 I The valve opens to protect the machine if the maximum permissible work ing pressure is exceeded The machine may only
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13. Motor and Power Drive motor Rated power RW Rated speed rpm KCT 110 1800 KOT 230 io KCT 420 io Enter the information on the motor nameplate in the table Tab 8 Drive motor data 2 8 2 8 1 2 8 2 KAESER COMPRESSORS Technical Specification Single Phase Power Supply Power supply The machine is designed for an electrical supply according to National Electric Code NEC NEC 670 particulary NFPA 79 section 5 7 In the absence of any user specified alternatives the limits given in these standards must be adhered to Consult manufacturer for any other specific power supply Electrical power connection The following multi strand copper core wires are given according to 2002 NEC 310 15 Table 310 16 for 40 C ambient temperature If other local conditions prevail like for example high temperature the cross section should be checked and adjusted according to 2002 NEC 110 146 220 3 310 15 Table 310 16 430 6 430 22 430 24 and other local codes Dual element time delay fuses are selected according to 2002 NEC 240 6 430 52 and tables 430 52 430 148 and 430 150 We strongly suggest using a separate copper conductor for the equipment GROUNDING NEC Table 250 122 will point out the minimum size however we recommend a ground conductor the same size as the power leads if local codes allow Rated power supply 115V 5 1 60Hz Main di
14. SERVICE MANUAL Reciprocating compressors Model Dental T GL no 9 5861 03 USE KAESER COMPRESSORS Contents Chapter page 1 Regarding this Document 1 1 1 1 Handling the Document 1 1 1 2 Further 5 enge aware RE GER 1 1 1 3 pee eee EP ES 1 1 1 4 Symbols and Identification 1 1 1 4 1 Warning notices 1 1 1 4 2 Other notices and symbols 1 2 2 5 2 3 2 1 Weight es toasters teeta fear sila Meade Portela a teehee 2 3 2 2 Compressor Block 000 cece eee ene enn 2 3 2 3 Ambient Conditions 2 3 2 4 Pressure Switch Setting 2 4 2 5 Pressure Maen teat LN QUO Hen tame entrar 2 4 2 6 Sound Pressure 2 4 2 7 Motor and Power hae ante ee a 2 4 2 7 1 Drive motor c teed ee Bee eS Gee eee Bes 2 4 2 8 Single Phase Power Supply 2 5 2 8 1 Power btt nda ADS Ae Ea rubi Vds 2 5 2 8 2 Electrical power connection
15. Checking Direction of Rotation The machine is designed for a clockwise field Check the supply with a phase sequence indicator compressor motor turns in the wrong direction change the motor supply phases L1 and L2 I Alternatively the direction of rotation can be checked by briefly switching the machine on and off again gt Switch the machine off as soon as the direction of rotation is seen and compare it with the direction arrows on the fan guard Initial Start Up Open the shut off valve to the compressed air system Switch on at the main power supply disconnecting device e T I Turn the switch on the pressure switch to the I position The machine switches to LOAD status and delivers compressed air I Keep an eye on the machine during the first few hours of operation to en sure that it is operating correctly After the first 50 operating hours carry out the following work Check that all electrical connections are secure 7 26 KAESER RS COMPRESSO Operation 8 Operation The compressor is controlled automatically by the pressure switch Oil free Oil free compressor Do not pour oil into the crankcase Auto Accumulating condensate is automatically drained Fig 9 Switching on and off 1 Onloff switch Position 0 Position I AN Automatic restart DANGER TEE Serious injury is possible The machine restarts automatically when power i
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18. 9 29 9 1 FaultS AE 9 29 10 10 31 10 1 tegeret RM rente ir a eM o ace Od pr eS re deg 10 81 10 2 Maintenance Schedule 10 32 10 2 1 Regular maintenance tasks 10 32 10 2 2 Regular service work eee eee eee 10 32 KAESER COMPRESSORS 11 Spares Service 12 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 11 1 11 2 11 3 11 4 11 5 Decommissioning Storage and Transport 12 1 12 2 12 3 12 4 12 5 Changing the Filter Air Filter Maintenance Electric Motor Maintenance Checking the Safety Relief Valve AIFTOCOIVOE ene diac p ep ETE qq deen Cee kes Venting the Machine depressurizing Maintaining the Check Valve Seccomat Dryer Maintenance Inspecting or Replacing the Cylinder Head and Valves Logging Maintenance Work Note the nameplate Ordering consumable parts Maintenance Service Addresses
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20. Use e The machine is intended solely for industrial use in generating compressed air Any other use is considered incorrect The manufacturer is not liable for any damages re sulting from unspecified use or application The responsibility in case lies solely with the user e Specified use also includes compliance with the instructions in this manual Operate the machine only within its performance limits and under the permitted ambi ent conditions Improper Use Never direct compressed air at persons or animals t Donotuse untreated compressed air for breathing purposes Do notuse untreated compressed for any application that will bring it into direct con tact with foodstuffs t Cooling air warmed after passing through the machine may be used for heating pur poses but only when it poses no health risk to humans or animals If necessary the warmed cooling air should be treated to render it harmless Do notallow the machine to take in toxic acidic flammable of explosive gases or va pors t Do not operate the machine in areas in which specific requirements with regard to ex plosion protection are applied User s Responsibilities Observe statutory and accepted regulations Observe relevant statutory and accepted regulations during installation operation and maintenance of the machine For example nationally applied European directives and or valid national legislation safety and acciden
21. air pressure gt Isolate completely from the power supply all conductors and ensure the supply cannot be switsched on again lock off gt Check that no voltage is present Injury and or machine defects caused by improper use gt Maintenance should be performed by properly trained person nel only gt Read and understand manual and all safety labels before switching the machine on Never remove or cover safety labels 4 Voltage Touching electrically live components can cause serious injury or death t Isolate completely from the power supply all conductors and ensure the supply cannot be switsched on again lock off t Check that no voltage is present Serious injury can result from compressed air t Do not direct air stream at body Tab 12 Safety signs 12 3 7 3 7 1 3 8 3 9 Safety and Responsibility m Fig 1 Location of Safety Signs Emergency Fire fighting t Immediately disconnect the machine s voltage supply Suitable extinguishing agents e Foam e Powder e Carbon dioxide e Sand or earth Unsuitable or unsafe extinguishing agents e Intense water jet Environmental protection Store and dispose replaced parts in accordance with local environmental protection regu lations Observe relevant national regulations Warranty This service manual contains no independent warranty committment Our
22. at the latest every 5 years Inspecting or Replacing the Cylinder Head and Valves Have the function of the cylinder head and valves checked or replaced after 4000 operat ing hours or at the latest every 5 years by an authorized KAESER Service representative 10 38 KAESER COMPRESSORS Maintenance 10 12 Logging Maintenance Work Machine number Date Maintenance task carried out Operating hours Signature Tab 18 Logged maintenance tasks 10 39 KAESER COMPRESSORS Spares Operating Materiels Service 11 Spares Service 11 1 Note the nameplate Make sure to quote the data on the nameplate for all enquiries and spare parts orders 11 2 Ordering consumable parts AN Personal injury or damage to the machine may result from the use of unsuitable consumables WARNING Unsuitable or poor quality consumable parts may damage the machine or severely impair its proper function Damage to the machine can also result in personal injury tx Always use genuine parts Have an authorized KAESER Service representative carry out regular maintenance KAESER consumable parts and operating materials are genuine spares They are de signed for use in KAESER machines Machine Name Number Dental TT 6 02060 Dental 3T Kit 4 1 402076 0 The filter kit consists of Air filter insert Filter mat Dental 3 2T Kit 4 2 402076 0 The filter kit consists of Air filter insert Filter mat
23. be operated with a correctly functioning pressure relief valve Adjusting the safety valve is not permitted and doing so invalidates all liabil ities Fig 12 Checking the safety relief valve 1 Knurled knob 2 Pressure relief valve t Close the user s shut off valve between the machine and the compressed air system Turn the knurled knob 1 on the pressure relief valve 2 anticlockwise until air blows off Then turn the knurled knob back to its original position AN Do not overtighten the knurled knob CAUTION tx a defective safety valve replaced by KAESER service Open the user s shut off valve between the machine and the compressed air system Switch on the machine 10 35 KAESER COMPRESSORS Maintenance 10 7 Air receiver e I Air receivers must be inspected at regular intervals in accordance with le gal requirements Observe national regulations The machine is fitted with a compressed air dryer Seccomat If the dryer works correctly no condensate will be precipitated in the air receiver Opening the condensate drain tap 1 once a month to check correct functioning of the dryer e I If condensate accumulates it should be collected in suitable container and disposed of according to environmental regulations and authorized KAESER Service representative informed 10 8 Venting the Machine depressurizing Pre condition Machine switched off Power su
24. continu Air inlet filter clogged Clean or replace the filter ously but final pressure is plate leaking or dam Check or clean the valve not reached aged plate Valve reed broken Replace valve plate Machine leaks air Seal leak or replace leaking part Leakage from an air con Check possible leakage sumer connected to the net points work The air demand is greater Use a larger machine than the capacity of the compressor Machine cuts in and out too Air receiver filled with con Drain condensate often densate Check the Seccomat dryer The machine switches off Check valve defective Replace the check valve and air escapes from the venting valve Air leaks from the pressure Defective switch diaphragm Replace the pressure switch while the machine is switch running The safety relief valve blows switch incorrectly Check setting off before the cut out pres set sure is reached Valve spring defective Replace the safety relief valve Dirt on the valve seat Let the safety relief valve blow off briefly Tab 15 Faults and Remedies Whistling sound from the Cylinder head bolts loose Tighten cylinder head bolts cylinder head Gasket defective Replace gasket KAESER COMPRESSORS Maintenance 10 Maintenance 10 1 Safety Disregard of these instructions and or incorrect handling can result in serious inju ries AN Voltage DANGER There is danger of fatal injur
25. e o _ Year I MWP FAD at ee Tank eee Voltage a HZ RPM Rhase HP _ y FLA p _ _ Tab 1 Nameplate Weight Maximum weight is shown Actual weight of individual machines is dependent on equip ment fitted Machine with sound enclosure Tab 2 Machine weight Compressor Block LUE Demum Deme cfm 75 psig cfm ders Tab 3 Compressor block data Ambient Conditions Maximum elevation above sea 3000 level ft Ambient temperature F 40 95 Higher elevation permissible only after consultation with the manufacturer Tab 4 Ambient Conditions 2 4 2 5 2 6 2 7 2 7 1 KAESER Pressure Switch Setting Factory setting Cut in pressure psig Cut out pressure psig Pressure differential Ap psi o 5 Pressure Switch Setting Pressure Maximum working pressure see nameplate Maximum working pressure psig Safety relief valve blow off setting psig Tab 6 Safety relief valve activating pressure Sound Pressure Level Operational state e under load at rated speed rated delivery and rated pressure Measurement conditions e free field measurement to CAGI PNEUROP 2 3 at 1 m distance Sound pressure level dB A Sound pressure with dB A Dental 1T Dental 3T Dental 3 2 Dental ST 708 8 Dental 5 27 Rs Wes Wed Tab 7 Sound Pressure Level
26. faults and damage to the machine rr Give instructions on fire reporting and fire fighting measures Hazard areas The table gives information on the hazard areas dangerous to personnel Only authorized personnel may enter these areas 3 ft perimeter around the machine Installation or transport per sonnel All personnel excluded dur ing transport Beneath the lifted machine All personnel excluded Installation Within the machine Installation personnel 3 ft perimeter around machine and power lines 3 ft perimeter around the machine Operating personnel Maintenance Within the machine Maintenance personnel 3 ft perimeter around the machine Tab 11 Hazard areas 3 11 KAESER 3 5 Safety Devices Do not change bypass or disable safety devices Do not remove or obliterate labels and notices Ensure that labels and notices are clearly legible More information on safety devices is contained in chapter 4 Design and Function sec tion 4 4 Safety Devices 3 6 Safety Signs The table lists the various safety signs used and their meanings The diagram shows the positions of the signs on the machine Position Symbol O 3 Hot surface can cause burns t Let the machine cool down t Work carefully t Wear protective cloth and gloves not synthetics such as poly ester A Machine starts automatically Severe injury can result from rotating components electrical volt age and
27. free of acid alkaline forming substances particularly ammonia chlorine hydrogen sulphide 3 10 KAESER 3 4 3 3 4 4 Do not position the machine in warm exhaust air from other machines Ensure accessibility so that all work on the machine can be carried out without danger or hindrance Operation gt Keep the machine enclosure closed for safety and to ensure correct cooling function r Carry out regular inspections e for damage e of the safety devices e of parts needing monitoring Machines drawing in air from the surroundings should not be operate without an air filter Maintenance t Make sure the machine is disconnected from electrical power and vented before com mencing any maintenance work Wear close fitting flame resistant clothing Wear protective clothing as necessary Do not leave any loose components tools or cleaning rags or the machine Components removed from the machine still be dangerous Do not attempt to open or destroy any components taken from the machine Decommissioning disposal gt Drain out fluids and dispose of according to environmental regulations These include condensate for example rr Dispose of the machine in accordance with local environmental regulations Taking organisational measures gt Designate personnel and their responsibilities rr Give clear instructions on reporting
28. plastic sheeting Place sufficient desiccant e g silica gel inside the plastic sheeting Transport packaging A a palette and corrugated paper carton is required for overland transport to protect the machine from mechanical damage Consult an authorized KAESER Service representative for advice on packaging for sea or air transport Storage Pre condition The machine must be adequately packed tx Store the machine in a dry room where the temperature remains above 32 F t Prevent ingress of moisture and condensation 12 42 12 4 12 5 KAESER did De commissioning Storage and Transport Transporting Use only a fork truck or pallet truck Make sure the lifting equipment is adequate for the weight of the machine Pre condition Machine must stand on a suitable transport medium pallet OUO Fig 15 Transport using a fork lift truck or pallet truck K Disposal Pre condition The machine is taken out of service Remove old filters the machine over to an authorized disposal expert 12 43 KAESER COMPRESSORS Annex 13 Annex 13 1 Diagrams and Drawings 13 1 1 Dimensional drawing 13 44 K1_5352_0 10062407 0 01 KOMPRESSOREN Ersatz f r koch4 schaef1 2106 2005 Freigeg 22
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30. 0 32 KAESER COMPRESSORS Maintenance 10 3 Changing the Filter Mat The filter mat can be cleaned and should be changed after 1000 operating hours Pre condition Machine switched off Power supply disconnecting device locked out Machine cooled down Close the user s shut off valve between the machine and the com pressed air system E 10 0051 1 2 Fig 10 Changing the Filter Mat 1 Crankcase end cover Screw Unscrew the securing screws 2 remove the crankcase end cover 1 Renew filter mat Replace the crankcase end cover 1 Open the user s shut off valve between the machine and the compressed air system 4 4 M y Switch on at main power supply disconnecting device 10 4 Air Filter Maintenance Equipment Compressed air for blowing out Solvent based cleaning agent Spare parts as required Pre condition Machine switched off Power supply disconnecting device locked out Machine cooled down 10 33 KAESER COMPRESSORS Maintenance 10 5 10 0049 Fig 11 Air filter maintenance Air filter Air filter insert Rubber cap Inlet opening KR ODM The air filter insert 2 consists of foam Opening the air filter Remove of the rubber cap 3 Extract the filter element 2 Cleaning the filter element t Clean the filter element 2 with a solvent based cleaner
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33. 2 months t Have the motor bearings checked by an authorized KAESER Service representative 36 months t Have the overall technical condition checked by an autho rized KAESER Service representative Checking Installation and Operating Conditions Check and confirm all the items in the checklist before starting the machine eek Are all the conditions for installation fulfilled 52 E gt User s lockable supply disconnecting device installed 7 24 KAESER COMPRESSORS Initial Start up 7 4 7 4 1 Tab 14 Installation conditions checklist Motor Protection Overload Protection on Single Phase Motors Single phase motors are fitted with a so called thermal overload protection switch that is adjusted to a fixed value It ensures shutdown of the machine at levels of current above the value set on the motor overload protection switch 4 07 0002 1 Fig 8 Trip button 1 Trip button for the overload protection switch e pak 7 I If the machine is shut down by the thermal overload protection switch t switch off the user s main disconnect switch t X allow the motor to cool down press the trip button on the motor overload protection switch switch on the user s main disconnect If the motor overload protection switch shuts down the machine repeatedly over short peri ods have the compressor and or motor checked 7 25 7 5 7 6 KAESER COMPRESSORS Initial Start up
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36. Dental 5T Kit 5 1 402077 0 The filter kit consists of Air filter insert Filter mat Dental 5 2T Kit5 2 402077 0 The filter kit consists of Air filter insert Filter mat Tab 19 Machine maintenance parts Seccomat dryer Model Name Quantity Number Dental 1T Kit 1 1 402073 0 Maintenance kit comprising Filter element O ring Desiccant 1 3 Ib 11 40 KAESER COMPRESSORS Spares Operating Materiels Service Mode Number 402073 0 Dental 3T Kit 1 1 Maintenance kit comprising Filter element O ring Desiccant 1 3 Ib Dental 3 2T Kit 3 1 402075 0 Maintenance kit comprising Filter element O ring Desiccant 4 4 Ib Dental 5T Kit 2 1 402074 0 Maintenance kit comprising Filter element O ring Desiccant 2 2 Ib Dental 5 2T 1 402075 0 Maintenance kit comprising Filter element O ring Desiccant 4 4 Ib Tab 20 Seccomat dryer maintenance parts Maintenance Agreement gt Arrange a SIGMA AIR SERVICE maintenance agreement Benefits to you lower costs and higher compressed air availability SIGMA AIR SERVICE offers you authorised service technicians with KAESER factory training increased operational reliability ensured by preventive maintenance energy savings achieved by avoidance of pressure losses optimum conditions for operation of the compressed air system the security of genuine KAESER spare parts increased legal certainty as all regulations a
37. Use slings to lift the machine 6 20 COMPRESSORS Installation 6 4 6 5 06 0020 Fig 5 Antivibration mount 1 Antivibration mount 2 Hexagonal nut Remove the wooden frame from the air receiver feet t Secure the antivibration mounts 1 to the air receiver feet with hexagon nuts 2 Install the Compressed Air Connection Pre condition The compressed air system must be at atmospheric pressure Fig 6 Compressed air connection 1 Flexible hose line 2 Shut off valve Shut off valve 2 to be installed by the user in the connection line Conect to the compressed air system with a flexible hose line 1 Electrical Connection Main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC OSHA and any applicable local codes Use wire conductor dimensions and fuse ratings in accordance with local regulations Guide values are given in chapter 2 8 tx The user must provide the machine with a lockable supply disconnecting device This could be for example a disconnect switch with fuses If a circuit breaker is used it must be suitable for the motor starting characteristics Before initial start up Connect machine to the main power supply in accordance with the electrical dia gram in chapter 13 1 2 6 21 KAESER COMPRESSORS Installation 6 6 Sound Enclosure accessory The compressor may be retrofitted with a s
38. ake must be unobstructed and have a minimum distance of 20 inches to the nearest wall Consult authorized KAESER Service representative if these conditions can not be achieved If installed outdoors the machine must be protected from frost direct sunlight dust and rain Ensure accessibility so that all work on the machine can be carried out without danger or hindrance 05 0012 Fig 4 Installation recommendation 1 2 Natural convection Forced ventilation 5 18 5 2 2 5 2 3 KAESER Ventilation Values given are minimum guide values I Ifthe cooling air is insufficient a dangerous vacuum can be created in the com pressor room Make sure that the cooling air flows around the machine gt Ensure that the volume of air flowing into the compressor room is at least equivalent to that being removed from it by the compressor and exhaust fan gt Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually open Inlet aperture sq ft Forced ventilation Required extractor capacitiy cfm at static pressure and maximum cut in period AT 18 F Dental 1T Tab 13 Overview Ventilation Operating in a compressed air system When the machine is connected to an compressed air system the system operating pres sure must not exceed the
39. cal and compressed air de vices and take appropriate measures to safeguard persons and property e inthe case of machines with refrigeration dryers must be able to recognize the pos sible dangers of refrigeration devices and take appropriate measures to safeguard persons and property e must have received adequate training and authorization for the safe installation and maintenance on these machines Adherence to inspection schedules and accident prevention regulations The machine is subject to local inspection schedules Dangers The general safety instructions in this chapter indicate possible dangers and how to deal with them Special safety instructions are found in this service manual at the beginning of each chap ter or directly before operative instructions Safely dealing with sources of danger Information concerning the various forms of danger that can arise in connection with ma chine operation are found here Electricity t Allow only qualified electricians or trained personnel under the supervision of a quali fied electrician to carry out work according to electrical engineering regulations on electrical equipment t Before initial start up make sure that adequate protection against electric shock from direct or indirect contact with the machine is installed and checked KAESER Isolate all phases of the main power supply Check and ensure that no power is present Switch off any external po
40. can compromize func tion and safe working Safe machine operation Information on safe conduct when handling the machine is found here Transport rz Use suitable lifting gear that conforms to local safety regulations re Attach lifting gear only to suitable lifting points on the machine Note the center of gravity to avoid danger of the machine tipping over r sure the danger zone is clear Installation Make sure no power is applied when electrical connections are made rr Only use only electrical cables that are suitable and approved for the electrical loads applied r Install or remove pressure lines only when they are vented rz Only use pressure lines that are suitable and approved for the maximum working pres sure and medium used gt Do not allow connection pipes to be placed under mechanical stress Do not step onto machine components to climb up the machine Location r Install the machine in a suitable room If installed outdoors the machine must be protected from frost direct sunlight dust and rain rr The machine is not explosion proof Do not operate in areas in which specific requirements with regard to explosion pre vention are applied rz Ensure adequate ventilation Observe the required ambient conditions e Ambient temperature and humidity e Clean inlet air with no damaging contaminants e Inlet air free of explosive or chemically unstable gases or vapours Inlet air
41. ction de vice trips after a short time Overcurrent protection de vice trips after a long time Fuse blown or circuit Check motor connections breaker tripped and fuses circuit breakers Defective pressure switch Replace pressure switch contact Overcurrent protection de Allow the motor to cool vice tripped down Motor defective bearing Contact authorized damage or windings KAESER Service represen shorted tative Compressor block defec Contact authorized tive KAESER Service represen tative Bearing damage Contact authorized KAESER Service represen tative Piston seized piston PTFE Contact authorized guides worn KAESER Service represen tative Fault in the power supply Check power supply Starting or running capaci Replace the starting or run tor faulty ning capacitor Ambient temperature too Reduce ambient tempera high ture Wrong direction of rotation Change the connections to the drive motor Fan cannot draw air freely Arrange unrestricted flow of air to the fan Valve plate leaking or dam Check or clean the valve aged plate Valve reed broken Replace valve plate Fault in the power supply Check power supply Motor fault Contact authorized KAESER Service represen tative Current too high because of Check supply cable low voltage cross section Check and tighten connec tion terminals 9 29 KAESER Faut Possible cause Remedy Compressor runs
42. e I Silencer Drying the compressed air The hot oil free compressed air leaving the block is cooled by the aftercooler before enter ing the dryer Any condensate arising is accumulated in the dryer s pre separator and drained at each regeneration cycle The dryer delivers clean and dry compressed air Desiccant regeneration When the machine is switched on the timer module begins the start phase T1 The compressor runs under LOAD and usable compressed air is produced When the period runs out the regeneration phase T2 begins and the desiccant is regener ated for 15 seconds during which time usable compressed air is not available 4 16 KAESER COMPRESSORS Design and Function 4 4 4 5 4 5 1 After completion of the regeneration phase the timer module switches to the operating phase T3 and the machine delivers usable compressed air again At the end of the operating phase T3 comes another regeneration phase T2 This alternating between and T2 repeats until the air receiver reaches cut out pressure and the compressor switches off This method of regeneration purging with full compressor delivery rate at reduced pres sure reduces regeneration time to a minimum coupled with high machine availability 80 90 depending on machine model Safety Devices The following safety devices are provided and may not be changed e Safety valve The safety valve protect
43. e Equipment Compressed air for blowing out Cleaning rags Spare parts as required Pre condition Switch off and lock out the main supply isolator Machine is fully depressurized pressure gauge reads 0 psig Machine is cooled down The user s shut off valve between the machine and the compressed air system is closed The check valve is installed on the air receiver inlet port It prevents the return flow of com pressed air from the receiver to the compressor AN Hot components danger of burns CAUTION Wear long sleeved clothing and gloves Work carefully 10 0009 Fig 14 Cleaning the check valve 1 Check valve 4 Valve seat 2 Screw plug 5 Spring 3 Valve cone 6 O ring Cleaning the check valve Remove the screw plug 2 Clean the valve cone 3 and seat 4 I Replace the valve cone 3 spring 5 and O ring 6 if they are badly worn Replace the check valve if the valve seat is damaged 10 37 10 10 10 11 KAESER COMPRESSORS Maintenance r Insert the valve cone spring and O ring in the valve seat r Screw in the plug 2 Start the machine and carry out a test run gt Open the user s shut off valve between the machine and the compressed air system Switch the machine gt Carry out a visual check for leaks Seccomat Dryer Maintenance I The dryer must be maintained by authorized KAESER Service representa tive every 10 000 operating hours or
44. ection Venting valve Timer module Solenoid valve Seccomat dryer Atmospheric air is drawn through a filter 1 into the compression chamber of the block 2 The air is drawn in during the downward stroke of the piston Air in the compression cham ber is compressed by the piston s upward stroke Compressed air is forced past the check valve 3 into the receiver 4 The check valve prevents the reverse flow of compressed air from the receiver to the compressor block 4 15 4 2 4 2 1 4 3 4 3 1 4 3 2 4 3 3 KAESER COMPRESSORS Design and Function Operating States and Control Modes Operating states There are two operating states e LOAD Surrounding air is drawn in through a filter and compressed Compressed air is discharged passed a check valve into an air receiver The compressor motor runs under full load e STANDSTILL Air is not compressed The check valve prevents already compressed air flowing back into the compressor The compressor motor is stopped Compressed Air Drying Function diagram Compresse d air 4 2 solenoid valve Aftercooler lt Purge air D V Microfilter H Em gt Air filter Compressor Desiccant Q A t Check valve 2L 18 Pre separator Pk Shut off valve Pneumatic 2 2 way venting valv
45. general terms and conditions of business apply with regard to warranty A condition of our warranty is that the machine is used for the purpose for which it is in tended under the conditions specified Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application Obtain confirmation from the manufacturer that the machine is suitable for your spe cific application Furthermore we accept no warranty obligation for e the use of unsuitable parts or operating materials e unauthorized modifications e incorrect maintenance e incorrect repair Correct maintenance and repair includes the use of genuine KAESER spare parts and op erating materials 3 13 KAESER COMPRESSORS Design and Function 4 Design and Function 4 1 Machine Overview 4 1 1 Primary components 2 4 1 5 4 2 04 0034 3 5 1 3 1 Fig 2 Major components Compressor block Drive motor Air receiver Pressure switch Seccomat 4 14 KAESER COMPRESSORS 4 1 2 Function 04 0035 Design and Function 13 7 4 12 4 Fig 3 Machine Overview 1 Air filter 8 2 Compressor block 9 3 Check valve 10 4 Airreceiver 11 5 Pressure relief valve 12 6 Pressure switch 13 7 Electric motor 14 Machine Pressure gauge Condensate drain Compressed air conn
46. hine is switched on Isolate all phases of the main power supply r Check and ensure that no power is present rz Wear close fitting clothes and a hair net if necessary gt Make sure all covers and safety guards are in place and secured before starting Temperature rz Avoid contact with hot components These include for example compressor blocks compressed air lines coolers motors and machine heaters rz Wear protective clothing If welding is carried out on or near the machine take adequate measures to ensure that no parts of the machine or any oil vapors can ignite because of sparks or heat Noise t Operate the machine only with soundproofing in place KAESER 3 4 2 Wear hearing protection if necessary The safety relief valve blowing off can be particularly loud Operating materials Strictly forbid fire open flame and smoking Follow safety regulations when dealing with chemical substances Avoid contact with skin and eyes Keep suitable fire extinguishing agents ready for use Use only KAESER approved operating materials 4 W WOW y Unsuitable spare parts gt Use only spare parts approved by the manufacturer for use in this machine Unsuit able spare parts compromise the safety of the machine Use only genuine KAESER parts for pressurized components Conversion or modification of the machine gt Do not permit conversion or modification of the machine as this
47. lief valve 10 35 Fig 13 Venting the machine cece Ih 10 36 Fig 14 Cleaning the check valve 10 37 Fig 15 Transport using a fork lift truck or pallet truck 12 43 KAESER Chapter page Tab 1 e te emet ad iq oe reed a Hanes 2 3 2 cece cece ete eee 2 3 Tab 3 Compressor block data ccc ccc ect s 2 3 4 Ambient Conditions 2 3 Tab 5 Pressure Switch Setting 2 4 Tab 6 Safety relief valve activating pressure 2 4 Tab 7 Sound Pressure Level dicere sei Dr Re or Haddad eect es 2 4 Tab 8 motor data se DER DERE 2 4 Tab 9 Power supply details 115V 1 60Hz 2 5 Tab 10 Power supply details 208 230V 1 60Hz 2 5 Hazardiareas s cives aed Gt ate eve teu kal Ete diee adele edi ae 3 11 12 Safety SIGNS 21 02 facie pee reg eee OEC HR CE quee 3 12 Tab 13 Overview 0 0 cc 5 19 Tab 14 Installation conditions checklist 7 25 Tab 15 Faults and Remedies
48. ll gladly help you in using the infor mation appropriately Symbols and Identification Warning notices IN Here are given the type and source of the danger DANGER Here are consequences of ignoring the warning notice The word DANGER means that death or severe injury can result if the warn ing notice is ignored gt Here are given the measures to protect yourself from the danger rz Always read and comply with warning notices Danger levels Warning notices indicate three levels of danger signified by the word below the danger sym bol Signal word Meaning Consequences of non compliance DANGER Warns of imminent threat Death or severe injury may result ening danger WARNING Warns of a possible threat Death or severe injury or serious damage to of danger the machine is possible CAUTION Warns of a possibly dan Light injury or damage to property possible gerous situation KAESER COMPRESSORS 1 4 2 Other notices and symbols Regarding this Document gt This symbol indicates that a task is to be carried out cs This symbol identifies environmental protection measures e I This symbol refers to particularly important information 2 1 2 2 2 3 COMPRESSORS Technical Specification 2 Technical Specifications The model designation and important technical information are given on the machine s nameplate Please enter the data from the nameplate here Part no Serial no
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50. n Mounts 6 20 6 4 Install the Compressed Air Connection 6 21 6 5 Electrical 6 21 6 6 Sound Enclosure accessory 6 22 6 6 1 Dismantling the sound enclosure 6 22 6 6 2 Fitting the sound enclosure 6 23 6093 even Blanes A Dre Edu 7 24 7 1 a mute ti erae iniit tocan e tesi ar at bsec c cese 7 24 7 2 Before Every 7 24 7 3 Checking Installation and Operating Conditions 7 24 7 4 Motor Protection We Mareen a KR eas a 7 25 7 4 1 Overload Protection on Single Phase 5 7 25 7 5 Checking Direction of Rotation 7 26 7 6 Initial Start Up aan RII 7 26 8 3565552 Deua esu Miah Le s E ER EO E EE s e 8 27 8 1 Switching On and Off 1 8 27 8 1 1 Switchilhig a a ER dati ee ayaa hee IS 8 28 8 1 2 Switchirig Off oa EDDA DE 8 28 9 Fault Recognition and Rectification
51. onnect up Bolt the front panel 5 to the rear panel 2 and fit the cover panel The machine s fan guard must fit flush with the foam see dimensional dia gram Open the access panel 7 with the toggle switch the machine on with the pressure switch and close the access panel again 6 23 7 7 1 7 2 7 3 KAESER COMPRESSORS Initial Start up Start up Safety AN Voltage DANGER Contact with live components can cause serious injury or death Isolate all phases of the main power supply switch off the mains supply disconnecting device Ensure that the power supply cannot be switched on again locked off t Check that no voltage is present AN Uncontrolled discharge of compressed air WARNING Serious injury or death can result from loosening or opening components under pressure Close shut off valves or otherwise isolate the machine from the air main to ensure that no compressed air can flow back into the ma chine t Vent all pressurized components and chambers completely The start up may only be carried out by authorized personnel Before switching on ensure that e one is working on the machine e all panels are in place and secured Before Every Start Up Only a trained specialist may carry out a start up of the machine Incorrect or improper start up can cause damage to the machine Special measures on start up after storage Storage period longer Remedy than 1
52. ound enclosure to reduce noise emission The sound enclosure is supplied ready assembled It must be dismantled for fitting to the machine AN Voltage DANGER There is danger of fatal injury caused by contact with live components t Isolate all phases of the main power supply switch off the main supply disconnecting device Ensure that the power supply cannot be switched on again locked off AN Uncontrolled discharge of compressed air WARNING Serious injury or death can result from loosening or opening components under pressure Close shut off valves or otherwise isolate the machine from the com pressed air system to ensure that no compressed air can flow back into the machine t Vent all pressurized components and chambers completely The machine pressure gauge must read zero 6 6 1 Dismantling the sound enclosure I Note how the parts fit together t Dismantle the sound enclosure 6 22 6 6 2 KAESER COMPRESSORS Installation Fitting the sound enclosure Fig KR DM hme 9 5 7 Fitting the sound enclosure Foot 5 Front panel Rear panel 6 Cover panel Machine 7 Access panel Antivibration mounts Fit the foot 1 onto the rear panel 2 Seat the machine together with the rear antivibration mounts 4 into the boreholes provided in the foot watch out for the motor size Push the cable and hose through the hols provided in the font panel and c
53. permissible operating pressure of the machine KAESER is ready to offer good advice 5 19 KAESER COMPRESSORS Installation 6 Installation 6 1 Safety AN Voltage DANGER There is danger of fatal injury caused by contact with live components Isolate all phases of the main power supply switch off the mains supply disconnecting device Ensure that the power supply cannot be switched on again locked off t Check that no voltage is present AN Uncontrolled discharge of compressed air WARNING Serious injury death can result from loosening or opening components under pressure Vent all pressurized components and chambers completely AN The solenoid valve is spring loaded CAUTION Close shut off valves or otherwise isolate the machine from the air main to ensure that no compressed air can flow back into the ma chine machine pressure gauge must read zero Installation work may only be carried out by authorised personnel All functioning parts are factory set Do not change these settings without the permission of the manufacturer 6 2 Reporting Transport Damage t Check the machine for visible and hidden transport damage t Inform the carrier and the manufacturer in writing of any damage found 6 3 Installing the Antivibration Mounts AN There is a danger of tipping because of the center of gravity and weight of the machine CAUTION t
54. pply disconnecting device locked out Machine cooled down AN Compressed air can cause injury or death DANGER Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly or uncontrolled Even when switched off the machine is still under pressure from the com pressed air system back to the check valve t Close the shut off valve provided by the user to isolate the machine from the compressed air system t Vent the air receiver Before undertaking any maintenance or service work on the pressure system the machine must be isolated from the air system and completely vented Vent the machine t Close user s shut off valve between the machine and the compressed air system e I If no shut off valve is provided the complete air system must be vented The machine is vented by means of the condensate drain tap 10 0048 Fig 13 Venting the machine 1 Condensate drain 10 36 10 9 KAESER COMPRESSORS Maintenance Open the condensate drain tap 1 slowly to release pressure t Check that the air receiver pressure gauge reads 0 psig e The pressure gauge does not read 0 psig after automatic venting c Make sure that the shut off valve is closed t If manual venting does not reduce the air receiver pressure gauge to 0 psig call authorized KAESER Service representative Maintaining the Check Valv
55. re kept to Service Addresses Addresses of KAESER are given at the end of this manual Spare Parts for Service and Repair I Any inspection maintenance or repair tasks not described in this manual should be carried out only by an authorized KAESER Service representa tive 11 41 12 12 1 12 2 12 3 KAESER De commissioning Storage and Transport Decommissioning Storage and Transport Decommissioning It is necessary to decommission the machine if e it will not be needed in the immediate future e is to be moved to another location e itis no longer needed e itis to be scrapped Temporary decommissioning Pre condition The machine can be started at regular intervals Runthe machine at operating temperature for at least 30 minutes each week Permanent decommissioning Pre condition The machine must have run for at least 30 minutes before permanent decommissioning The machine is switched off and fully vented The supply disconnecting device is switched off and locked out gt Allow the machine to cool down completely rr Disconnect all air and electrical connections rr Spray all electrical contacts and terminals with a protective lacquer e g Rivalto W S X Packing Equipment Desiccant Plastic sheeting Corrugated paper carton and a palette for transport packing Pre condition Machine is decommissioned Machine is dry and cooled down Wrap the machine in
56. s resumed after a power supply failure The machine is switched on by the pressure switch 8 1 Switching On and Off Always switch the machine on and off with the ON OFF switch The power supply disconnecting device has been installed by the user 8 27 KAESER COMPRESSORS Operation 8 1 1 8 1 2 Switching on AN Compressed air WARNING sh Serious injury is possible Never direct compressed air at persons or animals e I Before starting the machine ensure that e no one is working on the machine all panels are in place e no parts of the machine are colder than 40 F Switch on at the main power supply disconnecting device the ON OFF switch 1 to position I The compressor motor runs if compressed air system pressure is lower than the cut out pressure Switching off the ON OFF switch 1 to position 0 t Switch off and lock out the main power supply disconnecting device 8 28 9 9 1 KAESER Fault Recognition and Rectification Inform authorized KAESER Service representative if the fault cannot be rectified by the ac tion suggested Do not attempt rectification measures other than those given in this manual The alarm indications valid for your machine are dependant on the individual equipment Faults Faut Possible cause Remedy Machine does not start Machine starts with diffi culty Machine runs hot Overcurrent prote
57. s the system from excessive pressure This is factory set e Check valve The check valve prevents the flow of compressed air from the receiver back to the compressor block when the machine is stopped e Housing and covers for moving parts and electrical connections Protection from accidental contact Accessories Sound enclosure see chapter 6 6 The compressor may be retrofitted with a sound enclosure to reduce noise emission 4 17 5 1 5 2 5 2 1 KAESER Installation and Operating Conditions Surroundings M Strictly forbid fire open flame and smoking If welding is carried out on or near the machine take adequate measures to ensure that no parts of the machine can ignite because of sparks or heat The machine is not explosion proof Do not operate in areas in which specific requirements with regard to explosion pre vention are applied Observe the required ambient conditions e Ambient temperature and humidity e Clean inlet air with no damaging contaminants e Inlet air free of explosive or chemically unstable gases or vapors e Inlet air free of acid alkaline forming substances particularly ammonia chlorine or hydrogen sulphide Keep suitable fire extinguishing agents ready for use Installation Conditions Place of installation and space required Pre condition The floor must be level firm and capable of bearing the weight of the ma i chine The air filter int
58. sconnect Supply cable Rated current A fuse A AWG Dental 1T Tab 9 Power supply details 115V 1 60Hz Rated power supply 208 230V 5 1 60Hz Main disconnect Supply cable Rated current A fuse A AWG Dental 3T Dental 3 27 3 e Dental 5T Dental 5 27 35 8 _ Tab 10 Power supply details 208 230V 1 60Hz KAESER COMPRESSORS Technical Specification 2 9 Machine Duty Cycle A 100 duty cycle is possible on machines fitted with Seccomat e The pressure switch and the time module settings are precisely the particular machine type and may not be altered 3 3 1 3 2 3 3 3 3 1 KAESER Safety and Responsibility AN Disregard of these instructions can result in serious injury DANGER Read the service manual carefully and take notice of the contents for safe machine operation The machine is manufactured to the latest engineering safety standards and acknowl edged safety regulations Nevertheless dangers can arise through its operation e Danger to life and limb of the operator or third parties e Detrimental to the machine and proerty t Use this machine only if it is in a technically perfect condition and only for the purpose for which it is intended observing all safety measures and the instructions in the ser vice manual t n particular immediately rectify have rectified any faults that could be detrimental to safety Proper
59. t no one is working on the machine e all panels are in place and secured Maintenance Schedule e I Maintenance intervals are recommendations only and should be adjusted to suit installation and operating conditions t Keep a log of all service work This enables the frequency of individual maintenance tasks and deviations from KAESER s recommendations to be determined A prepared list is provided in chapter 10 12 Regular maintenance tasks I Maintenance tasks must be carried out more frequently when operating conditions are unfavorable e g dusty atmosphere or when the equipment is in frequent use interval Maintenance tasks 50 h after initial Check that all electrical connections are tight start up Every 1000 h or Air filter maintenance yearly Check that all electrical connections are tight h operating hours Tab 16 Regular maintenance tasks Regular service work e I Only authorized KAESER Service representatives should carry out service work Have service work should be carried out more frequently when operating conditions are unfavorable e g dusty atmosphere or when the equipment is heavily utilized Every 4 000 h or the cylinder head and valves every 5 years Change the motor bearings Generally overhaul the compressor every 10 000 h or maintenance of the Seccomat dryer every 5 years h operating hours Tab 17 Regular service work 1
60. t prevention regulations Qualified personnel Ensure that operating installation and maintenance personnel are qualified and authorized to carry out their tasks KAESER 3 3 2 3 4 3 4 1 These are people who by virtue of their training knowledge and experience as well as their knowledge of the prevailing conditions can assess the work to be done and recog nize the possible dangers involved Operating personnel Authorized operating personnel e must be adult e must be conversant with and adhere to the safety instructions and sections of the ser vice manual relevant to operation of the machine e musthave received adequate training and authorization to operate electrical and com pressed air devices e inthe case of machines with refrigeration dryers they must have training and qualifica tion for safe operation of refrigeration devices Installation and maintenance personnel Authorized installation and maintenance personnel e must be adult e must have read be conversant with and adhere to the safety instructions and sections of the service manual applicable to installation and maintenance e must be fully conversant with the safety concepts and regulations of electrical and compressed air engineering e inthe case of machines with refrigeration dryers must be conversant with safety con cepts and regulations relating to refrigeration equipment e must be able to recognize the possible dangers of electri
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62. wer sources These can be for example power supplied through a volt free dry contact or electri cal machine heating Use fuses corresponding to the machine power t Regularly check that all electrical connections are tight Compressed energy Compressed air is contained energy Uncontrolled release of this energy can cause serious injury or death Before working on a pressurized system t close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine vent all pressurized components and enclosures Do not carry out welding heat treatment or mechanical modifications to pressurized components e g pipes and vessels as this influences the component s pressure re sistance The safety of the machine is then no longer ensured Compressed air quality t Use appropriate systems for air treatment before using the compressed air from this machine as breathing air and or for the processing of food Never directly inhale compressed air Spring forces Springs under tension or compression represent contained energy Uncontrolled release of this energy can cause serious injury or death The solenoid valve is spring loaded Do not open or dismantle the valve Rotating components Touching the fan while the machine is switched on can result in serious injury Do open the enclosure while the mac
63. y caused by contact with live components t Isolate all phases of the main power supply switch off the mains supply disconnecting device Ensure that the power supply cannot be switched on again locked off AN Uncontrolled discharge of compressed air WARNING Serious injury or death can result from loosening or opening components under pressure Close shut off valves or otherwise isolate the machine from the com pressed air system to ensure that no compressed air can flow back into the machine t Vent all pressurized components and chambers completely The machine pressure gauge must read zero AN The check valve is spring loaded CAUTION Close shut off valves or otherwise isolate the machine from the com presse air system to ensure that no compressed air can flow back into the machine t Vent all pressurized components and chambers completely The machine pressure gauge must read zero Hot surface CAUTION Do not touch the surface tx Wear long sleeved clothing and protective gloves Leakage CAUTION Leaks cause loss of performance Damage or complete breakdown can result t Carry out a trial run after maintenance and service work t Carry out a visual check of the machine 10 31 KAESER COMPRESSORS Maintenance 10 2 10 2 1 10 2 2 e j Maintenance work may only carried out by authorized personnel Before switching on again ensure tha
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