Name: KAESER AIRTOWER 3C
Brand: KAESER
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Operator Manual

Screw Compressor

AIRTOWER 3C–7.5C Tri-Voltage

9_6917 34 USE

manroland-document-no.:

80.95A EN F254

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

http://www.kaeser.com

Table of Contents3
Regarding this Document Using this Document11
Further Documents11
Copyright11
Symbols and Labels11
Warnings11
Tab. 1 Danger Levels and Their Definition (Personal Injury)11
Potential Damage Warnings12
Other Alerts and Their Symbols12
Tab. 2 Danger Levels and Their Definition (Damage to Property)12
Technical Data Nameplate14
Options14
Tab. 3 Nameplate14
Weight15
Temperature15
Ambient Conditions15
Tab. 4 Options15
Tab. 5 Weight15
Tab. 6 Temperature15
Ventilation16
Pressure16
Fig. 1 Maximum Relative Humidity of Intake Air16
Tab. 7 Ambient Conditions16
Tab. 8 Ventilation16
Air Receiver17
Free Air Delivery (FAD)17
Cooling Oil Recommendation17
Tab. 9 Safety Relief Valve Activating Pressure17
Tab. 10 Air Receiver: Volume17
Tab. 11 Safety Relief Valve: Activating Pressure17
Tab. 12 Free Air Delivery17
Basic Information18
KAESER Lubricants18
Cooling Oil Charge19
Motor and Performance19
Compressor Motor19
Tab. 13 Cooling Oil Charge19
Tab. 14 Compressor Motor19
Tab. 15 Compressor Drive Motor Rated Speed19
Sound Emission20
Power Supply20
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral20
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral20
Tab. 16 Sound Emission20
Power Supply Specifications21
Tab. 17 Supply 208V/3/60Hz21
Tab. 18 Supply 230V/3/60Hz21
Tab. 19 Supply 460V/3/60Hz21
Refrigerated Dryer22
Tab. 20 Refrigerated Dryer: Model22
Tab. 21 Refrigerated Dryer: Compressed Air System22
Tab. 22 Refrigerated Dryer: Refrigerant System22
Power Supply Specifications23
Tab. 23 Power Supply 115V / 1 / 60Hz23
Safety and Responsibility Basic Instructions24
Specified Use24
Improper Use24
User's Responsibilities24
Observe Statutory and Universally Accepted Regulations24
Qualified Personnel25
Adherence to Inspection Schedules and Accident Prevention Regulations25
Dangers25
Safely Dealing with Sources of Danger25
Safe Machine Operation28
Organizational Measures30
Danger Areas30
Safety Devices30
Tab. 24 Danger Areas30
Working Life of Safety Functions31
Safety Signs31
Fig. 4 Location of Safety Signs31
Emergency Situations33
Correct Fire Fighting33
Treating Injuries from Handling Cooling Oil33
Tab. 25 Safety Signs33
Injury from Handling Refrigerant34
Warranty34
Environmental Protection35
Design and Function36
Enclosure36
Fig. 5 Enclosure Overview36
Machine Function37
Fig. 6 Machine Overview37
Refrigerated Dryer38
Air Receiver38
Safety Devices38
Fig. 7 Refrigerated Dryer38
Floating Relay Contacts39
Operating Panel SIGMA CONTROL BASIC39
Fig. 8 Keys - Overview39
Functional Description - SIGMA CONTROL BASIC40
Display Layout40
Fig. 9 Indicators - Overview40
Tab. 26 Keys40
Tab. 27 Indicators40
Parameter41
Tab. 28 Display41
Messages42
Tab. 29 Parameter42
Operating Modes and Control Modes43
Machine Operating Modes43
START-STOP Control43
Refrigerated Dryer Control Modes43
Options43
Machine Mountings44
Fig. 10 Machine Mountings44
Installation and Operating Conditions45
Ensuring Safety45
Installation Conditions45
Determining Location and Clearances45
Ensuring the Machine Room Ventilation46
Fig. 11 Recommended Machine Placement and Dimensions [In]46
Operating the Machine in a Compressed Air System47
Installation48
Ensuring Safety48
Reporting Transport Damage49
Connecting the Machine with the Compressed Air Network49
Connecting the Condensate Drain49
Fig. 12 Compressed Pipework49
Tab. 30 Condensate Line50
Tab. 31 Condensate Collecting Line50
Tab. 32 Condensate Collecting Line: Line Diameter50
Refrigerated Dryer: Connecting the Transformer According to the Power Supply51
Making the Power Supply Connection51
Fig. 13 Connecting the Condensate Drain51
Changing Main Voltage Connections52
Tab. 33 Voltage Selection52
Options53
Anchoring the Machine53
Tab. 34 Overload Protection Cutout Settings53
Initial Start-Up Ensuring Safety54
Instructions to be Observed before Commissioning or Re-Commissioning55
Checking Installation and Operating Conditions55
Tab. 35 Re-Commissioning after Storage55
Setting the Overload Protection Relay56
Pouring Cooling Oil into the Airend56
Fig. 14 Inlet Valve Filling Port56
Tab. 36 Installation Conditions Checklist56
Starting the Machine for the First Time57
Setting the Network Setpoint Pressure57
Operation59
Switching on and off59
Switching on59
Switching off59
Fig. 15 Switching on and off59
Switching off in an Emergency and Switching on Again60
Setting Parameters60
Fig. 16 Switching off in an Emergency60
Acknowledging Alarm and Warning Messages61
Fig. 17 Acknowledging Messages61
Fault Recognition and Rectification63
Basic Instructions63
Fault Messages (Machine Shut Down)63
Tab. 37 Fault Messages and Remedies63
Warning Messages64
Tab. 38 Warning Messages64
Other Faults65
Tab. 39 Other Faults and Remedies65
10 Maintenance66
Ensuring Safety66
Tab. 40 Warn Others that the Machine Is Being Serviced66
Following the Maintenance Plan67
Logging Maintenance Work67
Resetting Maintenance Interval Counters67
Regular Maintenance Tasks67
Cooling Oil Changing Interval68
Tab. 41 Regular Maintenance Tasks68
Regular Service Tasks69
Clean or Replace the Filter Mat69
Tab. 42 Oil Change Intervals Lubricants69
Tab. 43 Regular Service Tasks69
Cooler Maintenance70
Fig. 18 Filter Mat70
Air Filter Maintenance71
Fig. 19 Oil Cooler71
Compressor Motor Maintenance72
Maintaining the Drive Belt72
Fig. 20 Air Filter Maintenance72
Checking the Cooling Oil Level73
Fig. 21 Changing the Belt73
Venting the Machine (Depressurizing)74
Fig. 22 Checking the Cooling Oil Level74
Tab. 44 Permissible Cooling Oil Level under LOAD74
Fig. 23 Venting the Machine75
Replenishing Cooling Oil76
Fig. 24 Replenishing the Cooling Oil76
Venting the Machine (Depressurizing)77
Topping off with Cooling Oil and Carrying out a Trial Run78
Changing the Cooling Oil78
Fig. 25 Changing the Cooling Oil, Oil Separator Tank79
Changing the Oil Filter81
Changing the Oil Separator Cartridge82
Fig. 26 Changing the Oil Filter82
Fig. 27 Changing the Oil Separator Cartridge83
Checking the Safety Relief Valve Activating Pressure84
Checking the Compressor Safety Relief Valve84
Fig. 28 Compressor: Checking the Safety Relief Valve84
Checking the Air Receiver Relief Valve85
Performing the Test85
Fig. 29 Air Receiver: Testing the Safety Relief Valve85
Returning the Machine to Operational86
Check the Safety Shut-Down Due to Excessive Airend Discharge Temperature86
Testing the EMERGENCY STOP Push Button86
Fig. 30 Testing the EMERGENCY STOP Push Button86
Maintaining the Refrigerated Dryer87
Cleaning the Refrigerant Condenser87
Fig. 31 Refrigerated Dryer87
Maintaining the Condensate Drain88
Fig. 32 Checking the Condensate Drain88
Fig. 33 Changing the Service Unit89
Air Receiver Maintenance90
Fig. 34 Air Receiver Maintenance90
Documenting Maintenance and Service Work92
Tab. 45 Logged Maintenance Tasks92
11 Spares, Operating Materials, Service93
Note the Nameplate93
Ordering Consumable Parts and Operating Fluids/Materials93
Kaeser Air Service93
Tab. 46 Consumable Parts93
Service Addresses94
Replacement Parts for Service and Repair94
12 Decommissioning, Storage and Transport97
Decommissioning97
Packing97
Storage97
Transport98
Safety98
Transport with a Forklift Truck98
Transport with a Crane98
Fig. 35 Transporting with a Forklift Truck98
Disposal99
Fig. 36 Transporting with a Crane99
13 Annex101
Pipeline and Instrument Flow Diagram (P+I Diagram)101
Dimensional Drawing107
Electrical Diagram109

KAESER AIRTOWER 3C User Manual

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KAESER AIRTOWER 3C Specifications

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Brand	KAESER
Model	AIRTOWER 3C
Category	Air Compressor
Language	English