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KAESER EPC Series User Manual

KAESER EPC Series
110 pages
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Service Manual
2-stage piston compressor
EPC
No.: 9_9431_02 E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com

Table of Contents

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KAESER EPC Series Specifications

General IconGeneral
TypeRotary Screw Compressor
Drive TypeDirect Drive
Cooling SystemAir-cooled
Control SystemSigma Control 2.0
WeightVaries depending on model
Noise Level62 - 75 dB(A) (depending on model)

Summary

1 Regarding this document

1.1 Using the Document

Instructions on how to use and maintain the service manual throughout the machine's life.

1.2 Further Documents

Lists additional documents included with the service manual for safe machine operation.

1.3 Copyright

States that the service manual is copyright protected and directs queries to KAESER.

1.4.2 Other notices and symbols

Details symbols for important information, material, preconditions, options, and further topics.

2 Technical Specification

2.1 Nameplate

Details on machine identification and technical information found on the nameplate.

2.2 Options

Lists and describes available optional equipment for the machine, with option codes.

2.3 Weight

Information on the weight of the machine and its components.

2.4 Compressor Block

Specifications related to the compressor block, including displacement and cylinder count.

2.5 Ambient Conditions

Specifies permissible ambient temperature and altitude for operation.

2.6 Ventilation

Provides minimum guide values for inlet aperture and exhaust fan capacity.

2.7 Pressure switch setting

Details the factory settings for cut-in, cut-out, and differential pressure.

2.8 Pressure

Specifies activating pressures for various relief valves on the machine.

2.9 Sound pressure level

Presents sound pressure levels for different machine models under operating conditions.

2.10 Motor power and speed

Details motor power, speed, and degree of protection ratings.

2.11 Compressor oil recommendations

Recommends specific oils for the compressor and provides oil change intervals.

2.12 Power Supply

Covers basic requirements and specifications for three-phase power supply connections.

2.13 Network Conditions

Outlines network impedance requirements for machine operation with public power supply.

2.14 Machine duty cycle

Explains how to calculate duty cycle and provides valid values for ambient conditions.

4 Design and Function

4.1 Outline of the machine

Provides an overview of the machine and identifies its main components.

4.1.2 Machine function

Explains how the machine draws in, compresses, and delivers air.

4.2.1 Option C5 Oil level monitoring

Details the function of the oil level monitoring system and automatic shutdown.

4.2.2 Option C9 "pressure low" warning

Describes the 'pressure low' warning system for control centre notifications.

4.2.3 Option H1 Adjustable machine mountings

Explains the purpose and function of adjustable machine mountings.

4.2.4 Option H9 Silenced air filter

Details the benefits of the silenced air filter for noise reduction and air cleaning.

4.2.5 Option H10 Air filter with plastic casing

Describes the air filter suitable for unfavorable ambient conditions.

4.2.6 Option K5 / K6 ECO-DRAIN automatic condensate drain

Explains the automatic removal of condensate from the air receiver.

4.2.7 Option K7 Automatic solenoid valve condensate drain

Details the solenoid valve controlled condensate drain system.

4.2.8 Option P4 Pressure regulator with filter

Describes the function of the pressure regulator in reducing and stabilizing discharge pressure.

4.3 Operating modes and control modes

Describes the operational states (LOAD, STANDSTILL) and control mechanisms.

4.4 Safety Devices

Details the provided safety devices and emphasizes that they must not be modified.

5 Installation and Operating Conditions

5.1 Safety

General safety precautions related to installation, fire, and explosion protection.

5.2 Installation conditions

Covers requirements for location, clearances, ventilation, and network connection.

5.2.1 Determining location and clearances

Provides recommendations for machine placement and necessary clearances.

5.2.2 Ensuring adequate ventilation

Explains the importance of ventilation and requirements for air flow.

5.2.3 Operation in a compressed air network

Addresses considerations when connecting the machine to a compressed air network.

6 Installation

6.1 Safety

Instructions for safe initial start-up and working on machine components.

6.2 Reporting Transport Damage

Procedure for checking and reporting any damage incurred during transport.

6.3 Fitting the Antivibration Mounts

Guidance on correctly installing vibration-dampening mounts for the machine.

6.4 Compressed Air Connection

Instructions for connecting the machine to the compressed air system.

6.5 Connecting the Power Supply

Details on safely connecting the machine to the power supply by authorized personnel.

6.6.1 Option C5 Oil level monitor

Details the oil level monitor option and its connection and setting adjustments.

6.6.2 Option H1 Anchoring the machine

Instructions for securing the machine using adjustable mounting points.

6.6.3 Option K5/K6 ECO-DRAIN

Guidance on fitting the ECO-DRAIN automatic condensate drain.

6.6.4 Option P4 Pressure regulator

Explains how to install and set the pressure regulator with filter.

7 Initial Start-up

7.1 Safety

Safety instructions for initial start-up and working on live components or pressure systems.

7.2 Instructions to be observed before commissioning or recommissioning

Highlights the importance of correct initial start-up to prevent machine damage.

7.3 Checking installation and operating conditions

Checklist of items to confirm before the first start-up of the machine.

7.4 Motor protection

Details on the importance and setting of the motor overload protection switch.

7.5 Checking direction of rotation

Procedure for checking and correcting the machine's direction of rotation.

7.6 Starting the machine for the first time

Steps for safely starting the machine for the first time and checks after initial operation.

7.7 Measuring the air receiver charging time

Method for measuring air receiver charging time to check machine performance.

7.8 Setting network pressure

Instructions on adjusting the network working pressure to suit operating conditions.

7.9 Setting the regulator

Guidance on adjusting the filter regulator unit to maintain constant working pressure.

9 Fault Recognition and Rectification

9.1 Basic Information

General information on alarm indications and fault rectification measures.

9.2 Alarms

Lists common faults, their possible causes, and suggested remedies.

10 Maintenance

10.1 Safety

Safety instructions for performing maintenance work on the machine.

10.2 Maintenance Schedule

Guidelines for logging maintenance work and recommended intervals for tasks.

10.3 Maintaining the air cooler or fan guard

Procedure for cleaning the air cooler or fan guard to prevent overheating.

10.4 Air filter maintenance

Instructions for maintaining the air filter insert made of fibre mesh.

10.5 Air filter (noise absorbing) maintenance

Details on the maintenance of the noise-absorbing air filter element.

10.6 Air filter (with plastic casing)

Describes the maintenance of the air filter with a plastic casing.

10.7 Drive Motor Maintenance

Information regarding drive motor bearings, which require no re-greasing.

10.8 Checking the oil level

Procedure for checking the oil level using the oil sight glass.

10.9 Topping up the compressor oil

Instructions on how to safely top up the compressor oil, avoiding mixing types.

10.10 Changing the compressor oil

Steps for draining and refilling the compressor oil.

10.11 Testing the pressure relief valve

Guidance on testing pressure relief valves to prevent sticking and ensure safety.

10.12 Air receiver maintenance

Instructions for inspecting the air receiver and draining condensate.

10.13 Venting the machine (de-pressurising)

Procedure for safely venting the machine (de-pressurising) before maintenance.

10.14 Maintaining the check valve

Details on maintaining the check valve located at the air receiver inlet port.

10.15 Solenoid valve maintenance

Instructions for isolating the machine and venting before solenoid valve maintenance.

10.16 ECO-Drain automatic condensate drain

Describes checking and maintaining the ECO-Drain automatic condensate drain.

10.17 Solenoid valve maintenance

Instructions for cleaning or changing solenoid valves.

10.18 Filter pressure reducer cleaning

Procedure for cleaning the filter element in the pressure reducer unit.

10.19 Cylinder head and valves

Guidance on checking, cleaning cylinder head and valves, and tightening torques.

10.20 Document maintenance and service work.

Template for logging maintenance and service tasks performed on the machine.

11 Spares, Operating Materials, Service

11.1 Note the Nameplate

Emphasizes the importance of the nameplate for identifying the machine and ordering spares.

11.2 Ordering consumable parts and operating fluids/materials

Guidance on ordering original KAESER parts and materials, and warnings about unsuitable products.

11.3 KAESER AIR SERVICE

Highlights the benefits of KAESER AIR SERVICE for maintenance and operational reliability.

11.4 Service Addresses

Indicates that KAESER agent addresses are provided at the end of the manual.

11.5 Spare Parts for Service and Repair

Advises that tasks not described in the manual should be done by an authorized technician.

12 Decommissioning, Storage and Transport

12.1 De-commissioning

Procedures for temporary and long-term de-commissioning of the machine.

12.2 Packing

Advice on packing the machine for overland, sea, or air transport.

12.3 Storage

Precautions for storing the machine to prevent damage from moisture and frost.

12.4 Transporting

Safety guidelines and methods for transporting the machine using forklifts or cranes.

12.5 Disposal

Instructions for the proper disposal of the machine and its components.

13 Annex

13.1 Pipeline and instrument flow diagram (P+I diagram)

Provides the P+I diagram for the two-stage EPC unit.

13.2 Dimensional Drawing

Presents dimensional drawings and specifications for various machine configurations.

13.3 Electrical Diagram

Contains electrical diagrams for the machine, including circuit and component layouts.

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