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Air Compressor
Premium Compact W 160/4
KAESER Premium Compact W 160/4 User Manual
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Service Manual
Reciprocating compressor
Premium compact W
No.: 9_9418 20E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
2
Table of Contents
Default Chapter
1
Reciprocating Compressor
1
Table of Contents
3
1 Regarding this Document Using this Document
11
Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definitions (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
2 Technical Specifications Nameplate
14
Weight
14
Compressor Block
14
Tab. 3 Nameplate
14
Tab. 4 Weight
14
Tab. 5 Compressor Block
14
Ambient Conditions
15
Pressure Switch Setting
15
Pressure
15
Sound Emission
15
Tab. 6 Ambient Conditions
15
Tab. 7 Pressure Switch Setting
15
Tab. 8 Pressure Specifications
15
Motor Power and Speed
16
Compressor Oil Recommendations
16
Tab. 10 Power and Speeds
16
Tab. 11 Permissible Starting Frequency
16
Tab. 9 Sound Pressure Level
16
Compressor Oil Charge
17
Power Supply
17
Single Phase
17
Tab. 12 Compressor Oil Recommendations
17
Tab. 13 Compressor Oil Charge
17
Tab. 14 Mains Supply 110V/1/50Hz
18
Tab. 15 Mains Supply 230V/1/50Hz
18
Tab. 16 Mains Supply 110V/1/60Hz
18
Mains Conditions
19
Tab. 17 Mains Supply 115V/1/60Hz
19
Tab. 18 Mains Supply 127V/1/60Hz
19
Tab. 19 Mains Supply 220V/1/60Hz
19
Tab. 20 Mains Supply 230V/1/60Hz
19
Mains Conditions at 230V/1/50Hz
20
Machine Duty Cycle
20
Tab. 21 Network Impedance
20
Tab. 22 Machine Duty Cycle
20
3 Safety and Responsibility Basic Instructions
21
Specified Use
21
Improper Use
21
User's Responsibilities
22
Observe Statutory and Universally Accepted Regulations
22
Qualified Personnel
22
Adherence to Inspection Schedules and Accident Prevention Regulations
22
Dangers
23
Tab. 23 Inspection Intervals According to Ordinance on Industrial Safety and Health
23
Safely Dealing with Sources of Danger
24
Safe Machine Operation
25
Organisational Measures
27
Safety Devices
27
Safety Signs
27
Information Signs
28
Fig. 1 Location of Safety Signs
28
Tab. 24 Safety Signs
28
In Emergency
29
Correct Fire Fighting
29
Treating Injuries from Handling Cooling Oil
29
Tab. 25 Information Signs
29
Warranty
30
Environment Protection
30
4 Design and Function
31
Machine Function
31
Fig. 2 Machine Layout
31
Operating Modes and Control Modes
32
Operating Modes
32
Control Modes
32
Safety Devices
32
5 Installation and Operating Conditions
33
Ensuring Safety
33
Installation Conditions
33
6 Installation
34
Ensuring Safety
34
Reporting Transport Damage
34
Installation 6.1 Ensuring Safety
34
Compressed Air Connection
35
Connecting the Machine to the Power Supply
35
Fig. 3 Compressed Air Connection
35
7 Initial Start-Up Ensuring Safety
36
Instructions to be Observed before Commissioning or Re-Commissioning
37
Checking Installation and Operating Conditions
37
Motor Overload Protection
37
Tab. 26 Re-Commissioning after Storage
37
Tab. 27 Checklist of Installation Conditions
37
Resetting the Motor Overload Protection Switch for Single-Phase Motors
38
Measuring the Air Receiver Charging Time
38
Setting the Network Pressure
38
Fig. 4 Motor Overload Protection Switch
38
Tab. 28 Air Receiver Charging Time
38
Fig. 5 Setting the Network Pressure
39
Setting the Pressure Regulator
40
Fig. 6 Setting the Pressure Regulator
40
Tab. 29 Changing the Pressure Switch Setting
40
8 Operation
41
Switching on and off
41
Fig. 7 Switching on and off
41
Operation 8.1 Switching on and off
41
9 Fault Recognition and Rectification
42
Basic Instructions
42
Alarms
42
Tab. 30 Alarms and Remedies
43
10 Maintenance
44
Ensuring Safety
44
Maintenance Schedule
45
Logging Maintenance Work
45
Regular Maintenance Tasks
45
Oil Change Interval
45
Tab. 31 Regular Maintenance Tasks
45
Tab. 32 Oil Change Intervals
45
Regular Service Tasks
46
Fan Cowl Maintenance
46
Cleaning the Fan Cowl
46
Fig. 8 Cleaning the Fan Cowl
46
Tab. 33 Regular Service Tasks
46
Air Filter Maintenance
47
Drive Motor Maintenance
47
Fig. 9 Air Filter Maintenance
47
Checking the Oil Level
48
Topping up the Compressor Oil
48
Fig. 10 Checking the Oil Level
48
Changing the Compressor Oil
49
Fig. 11 Topping up the Compressor Oil
49
Pressure Relief Valve Checking
50
Air Receiver Pressure Relief Valve
50
Fig. 12 Changing the Compressor Oil
50
Air Receiver Maintenance
51
Fig. 13 Checking Pressure Relief Valve on the Air Receiver
51
Venting the Machine (De-Pressurising)
52
Fig. 14 Draining Condensate
52
Fig. 15 Venting the Machine
52
Maintaining the Check Valve
53
Fig. 16 Cleaning the Check Valve
53
Maintenance of the Pressure Switch Unloading Valve
54
Fig. 17 Maintenance of the Pressure Switch Unloading Valve
54
Cylinder Head and Valves
55
Documenting Maintenance and Service Work
56
Tab. 34 Logged Maintenance Tasks
56
11 Spares, Operating Materials, Service
57
Note the Nameplate
57
Ordering Consumable Parts and Operating Fluids/Materials
57
Kaeser Air Service
57
Fig. 18 Consumable Parts
57
Tab. 35 Consumable Parts
57
Service Addresses
58
Spares for Service and Repair
58
12 1 Decommissioning, Storage and Transport
59
Decommissioning
59
Packing
59
Storage
60
Transporting
60
Safety
60
Disposal
60
13 Annex
61
Dimensional Drawing
61
Electrical Diagram
63
5
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KAESER Premium Compact W 160/4 Specifications
General
Brand
KAESER
Model
Premium Compact W 160/4
Category
Air Compressor
Language
English
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