S1 - 2300manual Booster

SERVICE MANUAL
USE
Reciprocating Compressor
Model: N 753 --- G
145 psi / 500 psi
GL---Nr.: N753 ---G---1.2300.20570 ---02 ---40 ---YD 01
Part No.: 1.2300.20570

Serial No.: ...............................................
Table of Contents
Chapter --- Page
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1
1
1
1
2
2
2
2
3
3
5
Symbol and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous notices and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
2
2
-----------------
7
7
8
8
9
9
9
10
Proper Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Improper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
---------
11
11
11
11
Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12

4.1
4.2
4.3
4.4
4.5
4.6
-----------------------
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11
3.1
3.2
3.3
3.4
1
1
1
1
1
1
1
1
1
1
1
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

2.1
2.1.1
2.1.2
2.2
2.3
2.4
2.5
2.6
Booster Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Pressure Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing the Electrical Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Take the compressor out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting with a fork lift truck or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
4
4
-------------
12
12
13
13
13
14
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 15

5.1
5.2
5.3
5.4
5.4.1
5.4.2
Components of the Base---Mounted Booster Package . . . . . . . . . . . . . . . . . . . . . .

Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permissible cut ---in period (ED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tasks of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
5
5
-------------
15
16
17
18
18
18
Table of Contents
Chapter --- Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.1
6.2
6.2.1
6.3
6.4
6.4.1
6.4.2
6.5
6.6
6.7
6.8
6.8.1
6.8.2
6.8.3
6.8.4
6.8.5
---------------------------------
19
19
20
21
21
22
22
23
23
25
28
28
28
28
28
28
Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . .

Points to be Observed before Starting the Compressor Unit . . . . . . . . . . . . . . . . .
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Overload Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Inlet Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cut ---in frequency of the compressor unit from standstill to load . . . . . . . . . .
7
7
7
7
7
7
7
---------------
29
29
30
31
31
31
33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.1
8.2
8.3
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

7.1
7.2
7.3
7.4
7.5
7.6
7.6.1
Prevention of thermal problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the levelling discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to the low ---pressure network 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to the high ---pressure network 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . . .
Compulsory Safety and Regulating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flexible hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air inlet filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KAESER CONTROL Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown of the Compressor Package by Safety Devices . . . . . . . . . . . . . . . . . . .
Trouble Shooting: Possible cause --- Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor starts with difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor runs continuously, discharge pressure not reached . . . . . . . . . . . . .
Whistling noises at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety valve blowing off prematurely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil consumption of compressor too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor unit squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
8
8
8
8
8
8
8
8
8
-------------------------
34
34
35
36
36
36
36
36
37
37
37
37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.1
9.2
9.3
9.4
Observe the following rules during all maintenance and servicing work: . . . . . . .
Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular Maintenance of the Prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Check and Top ---Off (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
9
---------
38
39
40
40
ii
Table of Contents
Chapter --- Page
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.11.1
9.11.2
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9.19
Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning or Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning or Replacing the Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change the oil filter in the crankcase vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Oil Filter on the Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the aftercooler and check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning or Replacing the Dirt Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check and clean the dirt trap in the inlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check and clean the dirt trap on the crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the V---Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioning the V---belt(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V---Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check or Replace the Cylinder Heads and Valves (Compressor Block) . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
-----------------------------------
41
42
43
44
45
47
47
47
48
49
50
51
51
52
53
54
55
10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56

10.1
10.2
Service Parts and Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56

Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 58
11.1
11.2
11.2.1
11.2.2
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sensor Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
11
---------
58
79
79
79
iii
Technical Specification
1
1.1
Booster Unit
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 753 --- G
Overall weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1565 lbs
Maximum permitted pressure ratio . . . . . . . . . . . . . . . . . . . . 4.5:1
(see permitted duty cycle, chapter 5.3)
Diagrams:
Dimensional diagram . . . . . . . . . . . . . . . . . . . . . . . . 1.2300.20500
Electrical diagram . . . . . . . . . SKK---U0927.00 & SKK---U0947.00
P & I flow diagram . . . . . . . . . . . . . . . FKKN753 ---GST---00090.02
(Pipework and Instrument flow diagram)
1.2
Noise Level
Noise level to CAGI---Pneurop . . . . . . . . . . . . . . . . . . . . . . . . . . 80 dB(A)
at 1 m distance (free sound field measurement)
1.3
Compressor Block
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N 753
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 cfm
Capacity CFM (FAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.4 cfm
at 500 psig working pressure
Inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 ---145 psig
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 psig
Maximum duty cycle:
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 %
Pressure ratio
Pressure ratio 3 (load 60 min., idle 15 min.) . . . . . . . . . . . . 80 %
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 rpm
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 qts.
Oil top ---off quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 qts.
1.4
Drive Motor
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 hp
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm
Enclosure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC
Max. starts per hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 times
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wye---Delta
1 --- 1
1.5
Electrical Connection
Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 V 3 ---phase
Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . 80 A
Recommended power supply cable (Cu multi---stranded )
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AWG
Maximum dual element time --- delay fuses are selected according to
2002 N.E.C. Article 240 --- 6, 430 --- 52 and Tables 430 --- 52, 430 --- 148 &
150.
Attention!
Select multi--- strand copper core wire at 40 C ambient temperature

according to 2002 N.E.C. 110 --- 14(c), 220 --- 3, 310 --- 15, Table 310 --- 16,
430 --- 6, 430 --- 22, 430 --- 24 and Tables 430 --- 148 & 150.
Inlet Pressure Switch Setting

bar
1.6
12
MDR 43/11
11
Cut ---out pressure
10
Range of settings for

the inlet pressure switch
9
8
7
6
5
4
3
10 11 12
Cut ---in pressure
1.7
bar
Safety Relief Valve Setting

Set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 psig
1.8
Installation Requirements
Attention!
Ensure that the compressor package is level.

The floor must be solid with good loading characteristics.
The weight of the package is given in chapter 1.1.
Max. height above sea level at place of installation . . . . . . 3000 ft.

(for all heights above please contact authorized KAESER distributor)
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F
Max. ambient temperature* . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F
* For higher ambient temperatures the diagram in chapter 5 showing maximum cut ---in
duration must be taken into consideration.
Recommended minimum compressor space size
(floor area x room height) . . . . . . . . . . . . . . . . . . . . . 110 sq.ft. x 8 ft.
Ventilation of installation space
Inlet air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 sq.ft.
Exhaust air opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 sq.ft.
1 --- 2
1.9
Greasing the Electrical Motor

Relubricate the compressor motor bearings:
Relubricate interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 h*
* operating hours
See the motor nameplate for the quantity of grease to be used when regreasing.
Quantity per bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ________ oz
Bearing damages caused by the use of other brands of grease are excluded from the warranty.
Recommended lithium base saponified bearing grease:
Exxon Unirex N 3
EXXON Unirex N3 part numbers:
3.5 oz
part No.: 9.0915.0
14.1 oz
part No.: 6.3234.0
Replace the compressor motor bearings:

Under normal operating conditions,
after . . . . . . . . . . . . . . 36000 h*

(ambient temperature up to 77 F)
Under unsuitable operating
conditions, after . . . . . . . . . . . 20000 h*

(ambient temperature 78 F or more)
at the latest after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 years
* operating hours
1.10
Oil Recommendations
Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can
form in compressor oils. These deposits block the flow of lubricant and cause excessive
wear and failure of moving parts. Contamination of the oil can allow the formation of acids,
causing extensive internal corrosion. Water may be condensed decreasing the oils lubricity.
KAESER COMPRESSORS has several lubricants available that are specially formulated to
match these demands. They feature excellent lubricity, outstanding demulsibility (ability to
separate from water), and long life.
RECOMMENDED KAESER LUBRICANTS
SIGMA
DESCRIPTION
LUBRICANT
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
First Oil Change
Subsequent Oil
Change
M---150
ISO 100 Semi---Synthetic

Lubricant
50 Hours
1,000 Hours
S---150
ISO 100 Synthetic Lubricant
100 Hours
2,000 Hours
Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
1 --- 3
M --- SERIES SEMI --- SYNTHETIC LUBRICANTS
M---Series SIGMA compressor fluids are the highest quality petroleum lubricants.
M---150 is specially blended to provide reliable performance in KAESER reciprocating
compressors.
S--- SERIES SYNTHETIC LUBRICANTS
S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. These synthetic lubricants begin as high quality petroleum feed stock.
They are then refined, processed and purified into fluids with very consistent molecular
structure. These oils are carefully blended to produce extremely lubricants with superior properties. SIGMA synthetic lubricants feature all the advantages of both PAO and
diester fluids.
S---150 lubricant is recommended for compressors operating in ambient temperatures
between 40 F and 105 F.
Specialty KAESER LUBRICANTS
FG---150 synthetic hydrocarbon based food grade lubricant is designed for use in reciprocating compressors in the application where incidental food contact may occur
with the discharge air. This lubricant meets the requirements of the FDA Regulation 21
CRF 178.3570 and is USDA H ---1 approved. FG---150 is approved for canning, food
packing, meat and poultry processing and other applications where incidental food
contact may occur.
SPECIALTY KAESER LUBRICANTS
(Refer to product information to determine suitability.)
SIGMA
DESCRIPTION
LUBRICANT
FG---150
*
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
ISO 46 Food Grade

Synthetic Lubricant
First Oil Change
Subsequent Oil
Change
500 Hours
1,000 Hours
Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 500 hours (1,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
KAESER synthetic lubricant should be stored in a protected location to prevent contamination. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire---resistant fluid. It has a flash point above 460 F. Since the user has total control over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
1 --- 4
Compatibility:
FG---150 is similar to mineral oil in its compatibility with paints, seals, gaskets and
hoses. The typical precautions are required when changing over from mineral oil to
KAESER synthetic hydrocarbon based lubricant.
Never mix lubricants of different types or brands.
When switching from mineral oil to a synthetic oil, the plants system materials must be
re---evaluated. Certain plastics are not compatible with synthetic oils. The following is a partial list of acceptable and not recommended materials:
ACCEPTABLE
Viton
Celcon
PVC
High Nitrile Buna N
Neoprene
ABS
Teflon
Epoxy Paint
SBR Rubber
Low Nitrile Buna N
Oil Resistant Alkyd

Nylon
Acrylic Paint
Lacquer
Delrin
Polystyrene
Attention!
1.11
NOT RECOMMENDED
Polycarbonate bowls can be etched by any synthetic lubricant.

We recommend replacement with metal bowls, or the addition of metal
guards.
Dimensional Drawing
(see following page)
1 --- 5
Safety
2
Safety Regulations
Disregarding this notice can result in serious injury!
Read this service manual carefully and observe cautionary references before putting the
compressor unit into operation and before carrying out any maintenance on the unit.
2.1
Symbol and Identification
2.1.1
Warning notices
Here is a notice warning of danger.
DANGER
Here are consequences of ignoring the warning notice.

The word Danger indicates that death or severe injury can result from
ignoring the notice.
Always read and diligently comply with warning notices.
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the
danger symbol.
Signal word
Meaning
Consequences of ignoring the warning
DANGER
warns of imminent
threatening danger
death or severe injury or serious damage to

the machine
WARNING
warns of possible
threatening danger
death or severe injury or serious damage to

the machine is possible
CAUTION
warns of a possibly
dangerous situation
light injury or slight damage possible
This symbol is placed before all references to safety where danger to

life and limb can occur during work. It is important in such cases that
these notices are observed and that extreme care is taken. For their
own protection, all other users must be informed about these safety
notices. Observe general safety and accident prevention regulations
as well as the safety notices given in this service manual.
Attention!
This symbol is placed by text where considerable attention must be

paid so that directives, regulations, references and correct sequence
of work are adhered to and that damage or destruction of the machine
is prevented.
2 --- 7
Safety
2.1.2
Miscellaneous notices and symbols

This symbol identifies environmental protection measures.
This symbol indicates actions to be carried out by the user.
This bullet identifies listings.

This warning label identifies hot surfaces:
DO NOT TOUCH!
2.2
General Safety Precautions

Work on power driven systems may only be carried out by trained or
specialized personnel.
Work on the electrical equipment of the refrigerated dryer may only be
carried out by a qualified electrician or trained personnel under the
supervision of a qualified electrician according to the NEC and any applicable local codes.
Prior to working on electrical systems of the compressor always perform the following steps in the sequence shown.
1. Lock the main disconnect in the off position in accordance with
applicable lock out/ tag out procedures (example: OSHA CFR 29
1910.147) to ensure the compressor does not restart.
2. Ensure the package cannot be switched on again
3. Check that no voltage is present
4. Lock the isolation shut--- off valve in the closed position and vent
all compressed air trapped between the compressor and the isolation
shut--- off valve in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147).
Unless the Service Manual states otherwise, all pressure lines must be
vented or shut off.
Attention!
Any alterations or reconstruction carried out without the prior written

authorization of KAESER COMPRESSORS Inc. 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.
Attention!
Safety devices may not be modified or deactivated.

Signs and labels of reference may not be removed or rendered unreadable.
2 --- 8
Safety
2.3
Additional Safety Precautions

Attention!
Comply with the following:
Do not allow open flame and flying sparks at the installation site.
Take necessary precaution when welding on or near the compressor unit to ensure
that sparks or high temperatures cannot cause fire or explosion.
Ensure that the compressor unit is supplied only with clean uncontaminated air.
Do not allow the maximum ambient temperature to be exceeded (see chapter 1.8),
unless special measures have been agreed upon between the manufacturer and the
customer.
Perform oil changes according to the service manual or at least once annually.
Do not mix cooling oils of different types.
Use only cooling oils recommended by the manufacturer (see chapter 1.10).
This machine is not explosion ---proof.
It may not be operated in areas in which specific requirements with regard to explosion protection are applied.
2.4
Electrical Power Supply

Attention!
The main power supply and overcurrent protection must be installed

by a qualified electrician in accordance with NEC, OSHA and any applicable local codes.
Compressor units must be installed with a lockable main disconnect
and fuses or other short--- circuit and ground fault protection device.
For fuse and wire recommendations, see chapter 1.5
Please note that the conductors, fuses and procedure are Kaesers
recommendations. These recommendations do not supersede other
applicable codes.
2.5
Spare Parts
Safe and reliable operation of the compressor unit is guaranteed only with KAESER original
spare parts and KAESER SIGMA compressor oil.
2 --- 9
Safety
2.6
Environmental Protection
Condensate drainage
Condensate accumulating during compression must be drained via a
suitable draining system and collected in disposal canisters. The condensate must be disposed of according to environmental care regulations.
Maintenance materials/wear items/replacement parts
Dispose of all used materials and parts accumulating during operation, 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.
Dispose of all used materials and parts accumulating during operation, maintenance and repair of the compressor unit according to
Take the machine out of service (see chapter 8.1).
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.
2 --- 10
General
3
General
3.1
Proper Use of the Compressor

The compressor unit is intended solely for the purpose of generating compressed air. Any
other use is considered improper. The manufacturer cannot accept liability for any damage
caused by such improper use; the user alone is liable for any risks incurred.
Proper use of the compressor also includes compliance with the installation, removal, application, operational and maintenance instructions laid down by the manufacturer.
Attention!
3.2
The equipment may only be used or serviced by authorized and

trained personnel.
Improper Use
Never direct compressed air toward persons. Compressed air is a concentrated form of energy and as such dangerous to life.
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.
Attention!
Inlet air may not contain any explosive or chemically unstable gas or
vapour.
Initial filling of a fully vented air main generally creates very a high rate of flow through air
treatment devices.
These devices cannot function correctly under such conditions and compressed air quality
suffers.
KAESER recommends installation of an air main charging system to ensure required air
quality.
3.3
Copyright
KAESER COMPRESSORS, INC.
All rights reserved. No part of this manual may be reproduced in any form without permission of KAESER COMPRESSORS, INC.
3.4
Handling the Document

The service manual is part of the machine.
Keep the service manual safe throughout the life of the machine.
Pass the manual on the the next owner/user of the machine.
Ensure that all amendments are entered in the manual.
3 --- 11
Transport
4
Transport and Storage
4.1
Take the compressor out of service

The compressor must be correctly taken out of service in preparation for transport.
Switch the compressor 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.
Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29
1910.147) to ensure the compressor does not restart. See
chapter 2.4 for the main disconnect switch.
Wait at least five minutes before checking for electrical voltage.
Work carefully.
Isolate the compressor from the air main by closing the users compressed air inlet
and outlet shut ---off valves. Initial and final pressure gauges must read zero.
Allow the compressor to cool down completely.
If the compressor is water ---cooled, shut off the water supply, drain the water completely from the heat exchanger and dispose of it according to environmental regulations.
Disconnect all supply lines.
4.2
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.
Dispose of the packaging according to environmental regulations and
recycle where possible.
4 --- 12
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.
4.5
Transport Using a Crane

Attention!
If the compressor unit is transported by a crane the safety regulations

concerning lifting appliances must be observed.
Do not stand beneath hanging loads.
Do not exceed the maximum permissible lifting weight of the lifting appliance.
Attention!
Do not excert any side forces on the compressor unit when transporting with lifting equipment.
4 --- 13
Transport
4.6
Storage
The machine must be adequately packed.
Store the machine in a dry, frost ---free room.
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 operating 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:
change the oil filter (see chapter 9.9),
change the oil (see chapter 9.5),
have the motor bearings checked by an authorised 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
Have the the start ---up carried out by an authorised KAESER service
technician.
4 --- 14
Construction and Operation

5
Design and Function

This booster compressor is an air cooled, oil lubricated compressor using the principle of
single stage compression.
Compressed air from an air system is drawn in through the inlet port and the collector pipe
to the compression chamber of the compressor block. This compressed 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 center. After the piston has reached the bottom dead center position
the compressed air is boosted 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 boosted compressed air flows via an aftercooler pipe to the compressed air outlet.
5.1
Components of the Base ---Mounted Booster Package

13 12
14
16 3
26 11 2 7 24 23 22 21 20
17
10
19
1 15
18 25
KMZ052211
5 --- 15

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
5.2
Inlet port, entry of air from the low ---pressure air main
Compressed air outlet to the high ---pressure network
Compressor block, compresses the inlet air
Collecting pipe, collects and smoothes the incoming air
Aftercooler, collects and smoothes the compressed air and dissipates the heat
through the cooling fins
Check valve, prevents the escape of inlet air through the filter
Pressure relief valve, protects the compressor block from excessive pressure
Inlet valve
Control valve in the compressed air inlet
Relief valve, de ---pressurises the machine during standstill
De ---watering valve on the compressed air outlet
Air filter, cleans the intake air during idling
Electric motor, drives the compressor block
Casing venting with oil filter
Crankcase oil filter, cleans the compressor oil flowing through the oil pump integrated
in the crank case
Oil filler port
Oil level sight glass
Oil drain plug
Dirt trap in the compressed air inlet, cleans the incoming air
Dirt trap in the oil circuit, protects the oil pump from contamination
Temperature gauge switch, measures the compressed air discharge temperature and
switches the machine off if the maximum set value is reached
Oil pressure gauge
Initial pressure gauge
Final pressure gauge
Initial pressure switch, registers the inlet pressure and thereby regulates the switching on and off of the compressor
Temperature sensor, measures the block discharge temperature and switches the
machine off if the maximum set value is reached
Brief Description
The compressor block is driven by an electric motor via V---belts.
The compressor block may have one, two or three cylinders.
The belt pulley on the compressor crankshaft also serves as a fan to blow a stream of cooling air over the machine. Cooling fins on the cylinder and cylinder head dissipate heat.
A solenoid ---operated inlet valve is fitted at the compressed air inlet to the block.
A pneumatically operated venting valve, coupled with the control valve, is fitted to the aftercooler or base frame to de---pressurise the machine.
A further valve ensures de---watering of the pressure system.
The oil is pumped through a filter and returned to the crankcase.
A pressure switch ensures that the compressor runs only in the permitted initial pressure
range (see chapter 1.6).
5 --- 16

Permissible cut---in period (ED)
max.
Non ---permissible range
Ambient temp. 85 F, inlet temp. 95 F

Example
Up to 80% duty cycle
3.4
Up to 100% duty cycle
Compression ratio [PB(a)/P1(a)]
5.3
212
230
248
266
284
302
320
338
356
374
392
410
428
Final temperature [ F]
The maximum duty cycle (ED) of the booster is related to the compression ratio (discharge
pressure PB absolute / initial pressure P1 absolute), the ambient temperature and the compressed air inlet temperature (see diagram).
Example:
Initial pressure 160 psi (g)
Discharge pressure 580 psi (g)
Compression ratio: 594 psi (abs) / 174 psi (abs) = 3.4
Ambient temperature 105 F, inlet temperature 115 F
Results in a duty cycle (ED) of 80 %.
Duty cycle (ED) = Duty cycle (ED) is the portion of the total operating cycle that the
unit is under load.
ED [%] =
Time under load
x 100 %
Time under load + stationary time + time unloaded*
* if booster is equipped with load/unload (Dual) control.

Note: Duty cycle calculations are typically based on a 1 hour period.
5 --- 17

5.4
Operating States and Control Modes
5.4.1
Operating states
LOAD
The inlet valve is fully open. The airend delivers compressed air to the system.
The drive motor runs under full load.
IDLING
The inlet valve is closed. The check valve cuts off the machine from the air main. The
aftercooler is vented.
A small volume of air is drawn through the inlet filter into the compressor block and out
through the venting valve to atmosphere.
The drive motor runs without load and draws little current.
STANDSTILL
The inlet valve is closed. The check valve cuts off the machine from the air main. The
aftercooler is vented.
The drive motor is stopped.
Tasks of the Controller
Using the selected control mode, the controller switches the compressor between its various operational states in order to maintain system pressure between the set minimum and
maximum values.
DUAL
In DUAL control the compressor normally runs at full load and idle to maintain system
pressure between the set minimum and maximum values.
When the maximum pressure is reached the machine switches to idle running.
When the preset idling time has elapsed the machine is stopped.
Pressure
The shorter the idling time setting, the sooner and more frequently the motor is stopped.
The permitted starting frequency of the motor must not be exceeded.
p
max
p
min
Full load
Motor power
5.4.2
2 3
t1
5
t2
Idle
Standstill
Time
5 --- 18
Installation
6
Installation
6.1
Prevention of thermal problems

Ensure adequate air inlet and outlet appertures in the room (see chapter 1.8).
Correct location of the apertures (constant airflow).
Correct machine positioning (all machines must be able to draw in cool fresh air).
Hot discharge air must leave the room directly by the shortest path.
Do not exceed the permitted duty cycle .
6.2
Installation Instructions
To ensure sufficient cooling of the compressor unit the specified minimum compressor
location size, minimum distance to the walls and minimum size of the ventilation inlet and
exhaust openings must be complied with (see chapter 1.8).
The cooling air flow of the compressor unit is not greatly influenced in smaller locations
even if the door is opened, if the air flowing in through the door takes the shortest route to
the exhaust opening without flowing around the compressor.
Safe operation of the compressor unit is only guaranteed if the ambient temperature remains within the limits stated in chapter 1.8).
If the machine is installed together with other plant (compressors, refrigeration
dryers, etc.), then under no circumstances may the hot cooling air discharged from
that other plant be directed to the cooling air inlet end of the machine.
Exhaust
opening
31.5*
* Recommended
minimum door
width to allow
entry of
compressor
19.7
Inlet opening
Dimensions in inches
6 --- 19
Installation
6.2.1
Installing the levelling discs

Levelling discs are needed if a compressor is not standing level or if the antivibration pads
are not all equally loaded.
Attention!
Drive a fork lift carefully under the compressor and lift slightly.
There is a danger of tipping because of the centre of gravity and the
compressor weight.
2
1
3
1
2
3
4
Antivibration pad
Threaded hole for fixing the
antivibration pad under the compressor
Holes for rag bolts to fix the
antivibration pad to the floor
Compensating disc
to correct for uneven floor level
6 --- 20
Installation
Determine the positions where the levelling discs are to be installed.
Lift the compressor.
Remove the screws retaining the corresponding antivibration pads.
Insert the levelling disc between the compressor and the pad.
Re---secure the pad.
Attention!
If the compressor is equipped with a sound enclosure the rear panel of

the enclosure must be fitted before the antivibration pads are screwed
to the floor.
Position the compressor and fix to the floor with rag bolts.
6.3
Installation Instructions
The machine must be installed in accordance with the following diagram to ensure correct
operation with other plant.
It must be possible to isolate the machine by means of shut ---off valves on the inlet and
outlet to enable maintenance work to be carried out with the machine de---pressurised.
6.4
Connection of the Compressed Air Supply

The booster package is connected to an existing air system by a flexible hose.
A shut off valve must be connected between the air system and the inlet of the booster
compressor.
The discharge outlet has to be connected to the consumers via a flexible hose or pipework
with check valve.
The location of the compressed air inlet and outlet connections is shown in chapter 1.11.
Low pressure main 1
High pressure main 2
72.5 ---190 psig
up to 650 psig
Low pressure
consumers
Fine filter 1
High pressure
consumers
Prefilter
Separator
Fine filter 2
Rotary screw
compressor
Air
dryer 1
Air
receiver 1
Booster
Air
receiver 2
Air
dryer 2
Option
6 --- 21
Installation
6.4.1
Connection to the low--- pressure network 1

Connection to the low ---pressure network must be via a swans neck pipe. A prefilter, to
remove dust and condensate from the inlet air, is essential for reliable operation of the machine. The connection between the prefilter and the machine must be made with a flexible
hose.
Inlet air quality:
max. moisture 100% (drip free);
solid particles
1 m.
If there is no dryer between the machine and the air receiver in the low pressure network
then it is imperative that the prefilter is fitted with an automatic drain valve.
Furthermore, the machine must run in idle for approximately three minutes before shutdown to ensure that the inlet pipe is dry (idle control must be fitted).
KGB005021
1
2
4
1
2
3
4
5
6.4.2
Compressed air line

Low pressure network
Hose line
Prefilter
Machine (low pressure compressed air inlet)
Connection to the high--- pressure network 2

A flexible hose must be used to connect tie machine to the high ---pressure network.
KFB008221
5
6
5
6
Machine (low pressure compressed air inlet)

Machine (high pressure compressed air outlet)
6 --- 22
Installation
6.5
Electrical Connection
The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any applicable local codes.
For fuse and wire recommendations, see chapter 1.5.
The control box is wired ready for connection to the main supplies. Feed the supply cable
with cores marked L1, L2, L3 and PE through the cable inlet in the base frame of the control box and connect to the terminals marked L1, L2, L3 and PE in this box.
Attention!
Maximum dual element time --- delay fuses are selected according to
1996 N.E.C. Article 240 --- 6, 430 --- 52 and Tables 430 --- 148 & 150.
Select multi--- strand copper core wire at 40 C ambient temperature
according to 1996 N.E.C. 110 --- 14(c), 220 --- 3, 310 --- 15, Table 310 --- 16,
430 --- 6, 430 --- 22 and Tables 430 --- 148 & 150.
Wire temperature rating:
1.25 x FLA
(see chapter 1.5)
6.6
wire
temperature rating
correction factor
for 40 C
100A
60 C
0.82
100A
75 C
0.88
Controller Design
A controller that complies with EN 60 204 must be provided for connection to the power
supply.
The machine is fitted with a solenoid control valve that holds the pneumatic inlet valve
closed when not energised. The solenoid valve only opens when the air inlet is subjected
to a pressure at or above the cut ---in setting of the initial pressure switch (see chapter 1.6).
A number of components are wired together in the terminal box fixed to the compressor
(see diagram in chapter 11.1).
Six cables are fed into the terminal box (1):
1, 2, 3
temperature sensors, switching in series

(the machine shuts down if one of the sensors fails or a maximum temperature
value is exceeded).
Oil pressure switch (17.5psig).
Pressure switch for monitoring initial pressure.
Control valve (solenoid directional valve on the compressed air inlet)
Two cables are led out from the connection box:

1
Cable for the temperature sensors.
Cable ((oil pressure switch, pressure switch for monitoring initial pressure, initial
pressure valve)
6 --- 23
Installation
The additional electrical components required for the controller should be designed according to the corresponding motor power (see chapter 1.4).
The lines from the motor and the terminal box are connected in the controller and the following should be noted:
--- the oil pressure switch (17.5 psig) must be bridged in the motor run ---up phase and
must switch the compressor off at a pressure of < 14.5 psig.
--- the pressure switch that monitors initial pressure must switch the compressor on at a
pressure higher than pON and into idle running at a pressure lower than pOFF (see
chapter 1.6).
Attention!
The switch for monitoring initial pressure is factory set (see chapter 1.6)
and should not be adjusted.
If a final pressure is needed lower than the initial pressure setting, however, the setting can be changed (see chapter 7.6).
The ratio of initial to final pressure should not be higher than 1 : 4.5
If the pressure in the inlet line during the load phase falls below pOFF the compressor will
be switched by the pressure switch to idle running.
If, during offload running, the pressure in the inlet line falls below pOFF, the compressor will
only switch to load again when pressure pON is reached.
Pressure switch for monitoring initial pressure.
System pressure switch

fitted by the user
Compressor
p > pON
pmin < p< pmax
starts up
p > pOFF
p < pmax
runs under full load
p > pOFF
p = pmax
switches to idle running
p > pOFF
p = pmin
switches to full load running

*)
p < pOFF
pmin < p< pmax
switches to idle running *)
p < pON
Pmin
< p< pmax
remains or
switches to
idle running *)
* ) It is useful to record these alarms in the controller and indicate by a signal

Example of a machine with 145 psig initial pressure and 650 psig final pressure:
pON --- cut ---in pressure of the inlet pressure monitoring switch
(e.g. 145 psig)
pOFF --- cut ---out pressure of the inlet pressure monitoring switch
(e.g. 130 psig)
pmin --- cut ---in pressure of the air system pressure switch (user)
(e.g. 610 psig)
pmax --- cut ---out pressure of the air system pressure switch (user)
(e.g. 650 psig)
--- The PTC sensors must shut down the compressor if a temperature of 374 F is reached, even if only one sensor registers this temperature (series wired). The sensor
connections must be secure against wire breakage.
--- The adjustable temperature gauge switch (2) has volt ---free contacts that can be used
in the controller.
The compressor components are arranged in accordance with the P & I diagram.
6 --- 24
Installation
KFB010421
2
3
4
5
1
1
2
3
4
5
6.7
Terminalbox
Discharge temperature gauge
Pressure gauge (Oil pressure)
Pressure gauge (Pre ---pressure)
Pressure gauge (Discharge pressure)
Pipe and Instrument Flow Diagram (P & I Diagram)

(see following pages)
6 --- 25
Installation
6.8
Compulsory Safety and Regulating Equipment

Attention!
6.8.1
Safety and regulating equipment is supplied in a separate package

and must be installed by the user to ensure safe operation of the
booster unit.
Starter control box

The control box contents the control equipment of the booster unit like motor starter, overload relay and KAESER CONTROL. The starter control box has to be connected to the
booster package according to the wiring diagram in chapter 11.
6.8.2
Pressure switch
The pressure switch must be fitted for the regulation of the compressed air demand. This
pressure switch is normally fitted on the corresponding air receiver and regulates the
booster between the cut ---out and cut ---in pressures.
6.8.3
Flexible hose
The flexible hose is used to connect the booster package with an existing air system (air
receiver or pipework).
6.8.4
Check valve
To prevent the compressed air from flowing back into the compressor block, the check
valve must be fitted between the booster package and the air receiver.
Attention!
6.8.5
The size of the check valve depends upon the maximum working pressure (see chapter 1.3) and the cross--- section of the connection to the
air system (see dimensional diagram) from the compressor.
Air inlet filter

To ensure that the booster package is used only with clean air the air filter has to be fitted
to the air inlet connection.
starter control box
safety
relief valve
high
pressure
air system
main disconnect switch

high pressure
switch
shut--off
valve
flexible
hose
air filter
high pressure
tank with drain
trap
check
valve
existing
air system
booster package
Terminal box
6 --- 28
Initial Start
7
Putting into Operation
7.1
Points to be Observed before Putting into Operation

Every compressor unit is given a test run at the factory and carefully checked before shipment. 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 compressor 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!
Important functional components in the compressor unit (such as

check valve, safety relief valve and solenoid valve) are adjusted and
fitted to factory standards and specifications. Alterations to these components are not allowed without prior written authorization from the
manufacturer.
Do not disassemble the check valve, safety relief valve and solenoid
valve. They are heavily spring loaded.
7.2
Points to be Observed before Starting the Compressor Unit

ANY NON --- OBSERVANCE OF THIS OR OTHER REFERENCES (WARNING; ATTENTION; DANGER) CAN LEAD TO ACCIDENTS CAUSING INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
The compressor unit starts automatically after a power failure providing the line pressure is lower than the setting on the air pressure
switch.
Do not operate the compressor without belt guards or open doors as
injury to persons could occur from the drive belts and electrical equipment.
Remove all packaging materials, tools and transport securing devices on and in the
compressor unit.

It is expected that the user employs safe working techniques and that all lawful operating and safety regulations are followed when operating this compressor unit.
The operator of this compressor unit is responsible for its safe operating condition.
Do not operate this compressor unit in locations where heavy dust conditions, poisonous or inflammable gases could exist.
Do not connect the compressor unit to a supply voltage other than that stated on the
nameplate.
Install the compressor unit in a location not subject to freezing temperatures. The air
temperature requirements at the air intake must be complied with (see chapter 1.8).
During installation of the compressor unit, ensure that a distance of at least 19.7 is
kept between the air intake of the unit and any wall.
1910.147) to ensure the compressor does not restart.
Check all screws on the electrical connections for tightness and
tighten if necessary (carry out this check again after 50 hours of operation).
7 --- 29
Initial Start
7.3
Checklist
Is the floor at the place of installation level, solid and load ---bearing?
yes
no
Ist der Raum gro genug fr die Maschine oder deren Komponenten?
yes
no
Are inlet and exhaust air apertures available in sufficient size and number?
yes
no
Are all components easily accessible?

yes
no
Is the power supply cable of sufficient cross---section and the fusing adequate?
(have the electrical connection carried out by a qualified electrician familiar with local
conditions)
yes
no
Are shut off valves on the compressed air inlet and outlet fitted by the user?
yes
no
Are flexible connecting hoses fitted between the machine and the compressed air lines?
yes
no
Have all screws, bolts and electrical connections been checked for tightness?
yes
no
Has the oil level in the compressed been checked?

yes
no
Has the user installed a lockable main switch compatible with the motor starting characteristics?
yes
no
Has the setting of the drive motor overload current trip been checked?
yes
no
Have you ensured that there are no other air components located in the machines exhaust air flow?
yes
no
Has the operator been instructed in safety procedures and shown how to operate the
machine?
yes
no
If the aftercooler is water ---cooled, has the supply of water been ensured?
yes
no
Is the power supply as specified on the nameplate?

yes
no
7 --- 30
Initial Start
7.4
Direction of Rotation Check

Check the direction of rotation of the compressor block by switching the compressor
unit on 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.
7.5
Motor Overload Relay Adjustment

The relay is set to the standard adjustment at the factory.
Compressor motor: Wye --- delta start
In the Wye---delta configuration the phase current is fed through the motor overload relay.
This phase current is 0.58 times the nominal motor current.
For the nominal motor current see motor nameplate.
Adjustment:
The value can be set to a maximum of 10% higher than the calculated phase current to
prevent the overload relay from tripping under voltage fluctuations.
When the fault is removed the compressor can be started again by pressing the reset button on the overload protection trip.
7.6
Setting the Inlet Pressure Switch

See chapter 1.6 for pressure switch factory setting and pressure diagram.
Compressed air can cause injury!
WARNING
Serious injury can result from loosening parts under pressure.

Isolate the machine from the air main by closing the users
compressed air inlet and outlet shut ---off valves.
Attention!
Do not adjust pressure switch unless it is mounted and pressurized.

Do not set the maximum cut--- out pressure higher than the maximum
gauge working pressure (see chapter 1.1).
7 --- 31
Initial Start
KFB003521
5
---
3
---
1
3
Cap
Adjusting screw P
4
5
Adjusting screw p
Screw
Shut down the compressor unit (see chapter 8.1).


Unscrew the screws (5) to the right and left of the cover (1).
Remove the cover (1) of the pressure switch.
To increase the cut--- out pressure:

Turn the adjusting screw P (3) clockwise using a screwdriver. The red pin on the
pressure scale indicates the pressure.
Screw the plug back into the cover of the pressure switch.
To decrease the cut--- out pressure:

Turn the adjusting screw P (3) counterclockwise using a screwdriver. The red pin on
the pressure scale indicates the pressure.
Screw the plug back into the cover of the pressure switch.
To increase the pressure difference between the cut--- in and cut--- out pressures:
Turn the adjusting screw p (4) clockwise. The black pin on the differential pressure
scale moves in the max direction.
To decrease the pressure difference between the cut--- in and cut--- out pressures:
Turn the adjusting screw p (4) counterclockwise. The black pin on the differential
pressure scale moves in the min direction.
Replace the cover of the pressure switch.

Replace the cover after every adjustment of the pressure switch and
before starting the compressor unit.
7 --- 32
Initial Start
7.6.1
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 pressure difference between the cut ---in and cut --out pressures (switching difference). To change the cut ---in frequency the pressure switch
must be adjusted (see chapter 7.6).
Attention!
See chapter 1.4 for the maximum cut--- in frequency from standstill to
load per hour.
Increasing the switching difference causes a decrease in the cut ---in frequency.
Decreasing the switching difference causes an increase in the cut ---in frequency.
7 --- 33
Operation
8
Operation
8.1
Starting and Stopping the Compressor Unit

Starting the compressor unit
Switch on the main disconnect switch (see chapter 2.4).
Turn the control switch in the controller to the Start position.
Attention!
Check for correct direction of rotation when starting the compressor

unit (see chapter 7.4).
Stopping the compressor unit

Attention!
Do not stop the compressor unit with the main disconnect switch.
Always start and stop the compressor unit with the control switch in
the controller.
Turn the control switch in the controller to the Stop position.

Switch off the main disconnect switch.
See chapter 2.4 for the main disconnect switch.
8.2
KAESER CONTROL Safety System

The compressor unit is supervised by the KAESER CONTROL safety system.
The green LED (1) illuminates when the unit is ready for operation and during operation. It
is not illuminated during an alarm.
If an alarm occurs the red LEDs for the supervisory functions (2), (3) and (4) illuminate.
KAESER CONTROL
1
2
3
Motor
Temperature 1
Oil Pressure
Temperature 2
Supervisory functions with indication and shutdown:

2 Overload protection cut--- out for the compressor motor
If an overload occurs, the motor overload relay shuts down the compressor unit (see
chapter 7.5).
When the malfunction is corrected reset the compressor unit.
Turn the control switch to the 0 position.
Press the reset button of the overload protection switch.
Turn the control switch to the 1 position.
8 --- 34
Operation
3 Shutdown by high temperature in the cylinder head
The PTC sensor must shut down the compressor package if the temperature exceeds
374 F , i.e. even if only one sensor registers a temperature excess (this is why they are
connected in series). The wiring used to connect the PTC sensors must be open circuit
protected.
When the malfunction is corrected, reset the compressor unit by turning the control
switch from I to 0.
4 Shutdown by oil pressure switch
The compressor unit is shut down if the oil pressure in the crankcase is excessive or is
insufficient.
switch from I to 0.
5 Temperature gauge switch for detection of excess discharge temperature
If a temperature fault occurs the compressor unit is shut down by the temperature
gauge switch. (see chapter 8.3)
The compressor is started again after the fault has been removed.
8.3
Shutdown of the Compressor Package by Safety Devices

Shutdown by inlet pressure monitoring switch
--- The compressor package is shut down if the inlet pressure is insufficient (less than poff).
Shutdown by the oil pressure switch
--- The compressor package is shut down if the oil pressure upstream of the filter is too
high or too low.
Shutdown by PTC sensor
--- If a temperature of 375 F in the cylinder heads is exceeded the compressor package is
shut down by the PTC sensors. The PTC sensors are connected in series so that even if
the temperature is exceeded in only one cylinder head the compressor package is shut
down.
Switching off the machine via the temperature gauge switch.
The compressed air temperature is sensed directly at the discharge port of the oil separator. If it reaches 175 F, the switch inside the temperature gauge will cause the indicator
light at the KAESER CONTROL (see chapter 8.2) to come on and also shut the compressor
down.
Search for and correct the malfunction.
Possible malfunctions:

Low oil
Cooling system fault
Ambient temperature too high or too low
switch from I to 0.
Then restart the compressor unit (see chapter 8.1).
8 --- 35
Operation
8.4
Trouble Shooting: Possible cause --- Remedy

General safety regulations (see chapter 2) and local safety regulations
must be complied with during trouble shooting and repair procedures.
Starting after a repair (or malfunction):
See chapter 7 Putting into Operation.
Explanation of symbols for the following fault diagnosis:
1 --- have checked by a specialist.
2 --- contact your authorized KAESER distributor.
8.4.1
8.4.2
8.4.3
8.4.4
Compressor does not start

Possible cause:
Remedy:
No motor power supply, fuses blown.
Replace the fuses;
1.
Compressor starts with difficulty

Possible cause
Remedy
Inlet valve is not opening
Change the control valve
Damaged bearings
Replace the bearings or fit an exchange

compressor
Piston seized
(too little or wrong type of oil)
Change the cylinder and piston

(see chapter9.18)
Mains fault (phase dropout)
Check the power supply (fuses);
Oil level too high
Reduce the oil level to the maximum mark

(see chapter 9.4).
1.
Compressor overheating
Possible cause:
Remedy:
Ambient temperature too high

(over 105 F).
Lower the ambient temperature (see chapter 1.8).
Wrong direction of rotation

(observe the direction arrow).
Change over L1 and L2 terminals (see

chapter 7.4);
1.
The fan cannot draw in air freely.
Ensure that inlet air is available for the fan.
Valve plate leaking, varnished or the reed

valves are broken.
Check, clean or replace valve plate;

2.
und
Compressor runs continuously, discharge pressure not reached

Possible cause:
Remedy:
Valve plate gasket defective or wrongly

fitted
Fit new gaskets
Valve plate valves varnished up or defective
Clean or change the valves

(see chapter 9.18)
8 --- 36
Operation
Pressure losses within the unit
Brush soapy water on piping and fittings,

seal leaks or replace leaking parts
Air demand higher than the capacity of the

compressor
Increase the size of the compressed air

supply
Solenoid valve blowing off constantly, coil

burnt out or defective actuation
8.4.5
8.4.6
8.4.7
8.4.8
Whistling noises at the cylinder head

Possible cause:
Remedy:
Loose cylinder head bolts or defective gaskets.
Tighten the bolts or replace the gaskets;

1 and
2.
Safety valve blowing off prematurely

Possible cause:
Remedy:
Safety valve blows, even though the cut --out pressure is not yet reached.
Check that the pressure gauge functions

correctly, replace if necessary.
Check the pressure setting.
Defective valve spring.
Replace the safety valve;
Wrong set point.
Set 10 ---15 psig above max. working pressure (see chapter 1.1) of the compressor
1.
unit;
Safety valve was opened, dirt particles

stuck in valve seat.
Open the safety valve completely for a short

period to allow it to blow itself clean.
1.
Oil consumption of compressor too high

Possible cause:
Remedy:
Viscosity of oil too low.
Fill with correct oil

(see chapter 1.10);
1.
Defective crankcase venting system.
Clean the crankcase venting system or replace the filter;

1.
Piston rings worn or damaged.
Replace piston rings and cylinder;
Piston rings worn or damaged after only a

short period.
2.
Replace piston rings and cylinder;
(ensure that the inlet air is clean, e.g. by
using an air filter with a higher grade of filtration).
2.
Compressor unit squealing

Possible cause
Remedy
V---belt(s) slipping
Tension the V---belt(s)

(see chapter 9.12)
8 --- 37
Maintenance
9
Maintenance
9.1
Observe the following rules during all maintenance and servicing work:
Work on power driven equipment may only be carried out by trained or
specialized personnel. Follow all applicable OSHA and local safety
regulations.
The compressor unit restarts automatically after a power failure if the
line pressure is lower than the pressure setting on the air pressure
switch.
Lock the main disconnect switch in the off position in accordance
with applicable lock out/tag out procedures (example: OSHA CFR 29
1910.147) to ensure the compressor does not restart (see
chapter LEERER MERKER for main disconnect switch).
Ensure that no maintenance personnel is working on the compressor
unit, that all panels are latched back on again and all maintenance
doors are closed before restarting the compressor unit.
To start the compressor unit see chapter 8.1.
Attention!
Always tighten down any screw connection that has been loosened
during maintenance work.
The following points must be observed when handling lubricating and
cooling materials:
Avoid contact with skin and eyes.
Do not inhale vapors 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 --- 38
Maintenance
9.2
Regular Maintenance
Period*
Work to be done
See chapter
daily
check the oil level in the compressor block
9.4
2 and 24 hours after

first putting into operation and after changing
the V---belt
check the V---belt tension
9.12
50 hours after first putting into operation
check all electrical screw connections for tightness and tighten if necessary
7.2
500 hours after first

putting into operation
carry out a compressor oil change
9.5
change the crankcase oil filter
9.9
check and clean the air filter
9.6
check and clean the dirt trap
9.11
check the V---belt tension
9.12
check the safety valve
9.15
clean the solenoid valve jet
9.15
Proper interval varies

(see chapter 1.10) or at
least annually
carry out a compressor oil change
9.5
1000 hours
check and clean the check valve
9.7
clean the air cooler and check for leaks
9.10
grease the motor bearings
1.9
change the crankcase oil filter
9.9
check and clean the oil filter
9.8
5000 hours
check the cylinder head, piston rings and valves

for signs of excessive wear
9.18
12000 hours
carry out a general overhaul of the compressor
9.18
up to 20000/36000 h,
or at least every 8
years
Have the drive motor bearings changed by an

authorised KAESER Service agent.
1.9
500 hours or at least

annually
2000 hours
The maintenance period can vary depending on the cycle rate and environmental
conditions.
For severe duty (i. e. ambient temperature over 90 F, relative humidity over 90 %, or dirty
environment) the maintenance periods should be cut in half.
We highly recommend that a record is kept of the maintenance work done (see
chapter 9.19).
9 --- 39
Maintenance
9.3
Regular Maintenance of the Prefilter

Period
Work to be done
See chapter
Depending on filter
clean the prefilter in the inlet pipe
see manufacturers instructions
Attention!
9.4
If the appropriate cleaning regulations are not observed condensate

and dusty compressed air could be sucked in that could lead to destruction of the booster package.
Oil Level Check and Top ---Off (Compressor Block)

Check the oil level daily through the oil sight glass when the compressor unit is shut down.
Attention!
If the oil level has sunk to the lower mark, top off the oil immediately
according to the oil recommendations (see chapter 1.10).
Never top off to a level exceeding the maximum oil mark on the oil
level sight glass.
When topping off the oil always use a strainer or pour the oil directly
from the new oil can.
KFB069421
max.
min.
1 Oil top ---up plug

2 Oil level sight glass
Shut down the compressor (see chapter 8.1).
DANGER

Remove the crankcase venting plug (1) from the oil filler.
Attention!
Let oil settle a few minutes before filling to the maximum oil level mark.
The oil must flow through the crankcase first.
Top off the oil to the maximum mark. See chapter 1.3 for the quantity of oil required for
topping off from the minimum mark to the maximum mark.
Check the sealing ring of the filler plug (1) for damage and then replace the plug.
Open the users shut ---off valves when the machine is re---started.
9 --- 40
Maintenance
9.5
Oil Change (Compressor Block)

Oil change must be carried out with warm to the touch condition of the compressor unit
(Oil temperature approx. 104 F).
Danger of scalding with hot oil
Danger of burns from hot components
CAUTION
Wear long ---arm clothing and gloves.

Work carefully.
Change the oil after approximately the first 500 service hours.
For oil change requirements see chapter 1.10.
If, under unsuitable operating conditions, condensed water is observed in the oil, recognizable by the milky color in the oil level sight glass (2), carry out an oil change immediately.
Damage to the machine from unsuitable oil.
CAUTION
Never mix different types of oil.

Top up only with the same type of oil as already in the machine.
See chapter 1.10 for suitable oils.

KFB069321
max.
min.
3
1 Screw plug
2 Oil level sight glass
3 Oil drain plug
DANGER

Isolate the machine from the air main by closing the users compressed air inlet and
outlet shut ---off valves. Initial and final pressure gauges must read zero.
Remove plug (1) from the oil filler port.
Prepare a container to catch draining oil.
Danger of explosion from oils and lubricants!
WARNING
Danger of explosion from oil mist and vapours.

Fire, naked flame and smoken forbidden!
9 --- 41
Maintenance
Catch the used oil and dispose according to environmental regulations.
Remove the oil drain plug (3) and allow the oil to drain into the container.
Flush the crankcase with a small volume of fresh oil.
Replace the oil drain plug (3).
Attention!
A sieve should be used when refilling with fresh oil unless it is from a
new can of genuine Kaeser oil.
Replace the plug (1) in the oil filler port.

9.6
Cleaning or Replacing the Air Filter

The filter cartridge (3) of the air filter (1) consists of oil wetted knitted coconut fibre.
Do not exceed a maintenance interval of 500 service hours. Replace the complete air filter
if the cartridge is heavily contaminated or has been cleaned often.
KFB073821
1
1
2
3
4
Air filter
Air inlet
Filter cartridge
Snap fastener
DANGER

Work carefully.
Unscrew the air filter (1) from the collector pipe.
Unhook the snap fastener (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 --- 42
Maintenance
Clean the filter cap, especially the sealing surfaces.
Wash out the filter cartridge (3) with diesel fuel or clean with a steam jet.
When the filter cartridge (3) is dry wet lightly with oil.
Attention!
Make sure that the air inlet in the filter cap (2) is facing downwards
when screwing on the air filter .
Screw on the air filter (1), fit the cap.

Attention!
Replace the complete air filter if the cartridge is heavily contaminated

or has been cleaned often.
9.7
Cleaning or Replacing the Check Valve

The check valve is fitted between the collector pipe and the air filter. It vents the collector
pipe during idle mode.
Check and, if necessary, clean the check valve every 500 service hours or at least once
annually.
2
1
6
5
3
4
KFB073921
1 Check valve
2 End plug
3 Valve piston
4
5
6
Valve seat
Spring
Sealing ring
Shut down the compressor package (see chapter 8.1).

DANGER

Work carefully.
Isolate the compressor unit from the air system.

System pressure is present up to the check valve when the compressor unit is switched off. For this reason, the compressor unit must
be isolated from the air system (close the users isolation shut--- off
valve). If there is no isolation shut--- off valve fitted, the complete air
system must be vented. The pressure gauge must indicate zero psi.
9 --- 43
Maintenance
Attention!
Always wear ear protection when lifting the safety relief valve because
of the loud noise caused by the compressed air blowing off.
Vent the air receiver and the pipework by lifting the upper knurled ring of the safety
relief valve (1, see chapter 9.15) and blowing off the compressed air.
Check the pressure on the pressure gauge. It must indicate zero psi.
Unscrew the plug (2) in the check valve.
Clean the valve piston (3) and the valve seat (4).
If damage or heavy wear is noticeable replace the valve cone (3), the spring (5) and
the ring (6).
Screw the plug (2) in the check valve again.
9.8
Change the oil filter in the crankcase vent

A constant oil mist is created by the pressure in the crankcase. Because this oil mist
should not be allowed to escape to the open air the crankcase is vented via an oil filter (2)
that retains the oil.
If the booster unit runs continuously, the oil accumulating in the crankcase venting system
can increase to the point where it can no longer return to the crankcase.
Attention!
Do not run the booster unit without the oil filtered crankcase venting
system.
The oil filter (2) must be changed every 2000 operating hours.
3
4
2
1
1
2
3
4
Casing venting
Oil filter element
Venting cap
O ---ring
9 --- 44
Maintenance
DANGER

Switch off and lock out the main switch.
Work carefully.
Compressed air can cause injury!
WARNING
Serious injury can result from loosening parts under pressure.

Isolate the machine from the air main by closing the users
compressed air inlet and outlet shut ---off valves.
Check that the initial and final pressure gauges read zero pressure.
Unscrew the venting cap (3).

Escaping oil mist is damaging to health.
CAUTION
Do not inhale oil mist or vapour.

Take out the oil filter (2).

Dispose of the oil filter in accordance with environmental care regulations.
Insert the new oil filter (2).
Screw the venting cap (3) back again, checking the correct seating of the o ---ring (4)
for the pressure setting.
9.9
Changing the Oil Filter on the Crankcase

Attention!
Change the oil filter after approximately the first 500 service hours
Danger of scalding with hot oil
Danger of burns from hot components
CAUTION
Wear long ---arm clothing and gloves.

Work carefully.
It is recommended that the oil filter be changed every 2000 operating hours but in any
case when the oil is changed or if the oil pressure switch shuts down the compressor because of excessive pressure.
Changing the oil filter
Shut down the compressor package (see chapter 8.1).
9 --- 45
Maintenance
Work carefully.
Close the users shut ---off valve between the compressor package and the air main.
The compressors oil circulation system vents automatically.
The pressure gauge must indicate 0 psig.
KFB048621
2
1
1 Oil filter
2 Turn in this direction to remove
Escaping oil mist is damaging to health.
CAUTION
Do not inhale oil mist or vapour.

Twist the used or contaminated oil filter cartridge counter clockwise to remove and
catch escaping oil in a suitable container.
Dispose of the old oil filter and any used, accumulated oil according to
Clean the face of the combination block with a lint free cloth.
Lightly oil the gasket of the new filter cartridge before screwing into position.
Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.
Attention!
Do not use a tool as this may cause damage to the oil filter cartridge
and the gasket.
Check the oil level (see chapter 9.4).

Open the isolation shut ---off valve between the compressor package and the main air
system.
Carry out a trial run.
1910.147) to ensure the compressor does not restart. See chapter 2.4 for the main disconnect switch.
Carry out a visual check for leaks.
9 --- 46
Maintenance
9.10
Clean the aftercooler and check for leaks

Cleaning:
Machine damage from contamination
CAUTION
Contamination causes overheating and machine damage

Check for contamination every 1000 operating hours.
If the outlet temperature of the machine rises to 50 F above the established annual average, the aftercooler should be cleaned by a KAESER service technician.
Leakage check
Machine damage from leakage
CAUTION
Damage or complete breakdown can result.

Test run after maintenance or service.
Carry out a visual check of the machine.
The air aftercooler should be checked for leaks annually.

Especial attention must be paid to aging and corrosion of the cooler materials under long
term operating conditions. Condensate can escape from a leakage.
If the cooler is found to be leaking, shut down the machine immediately and remedy
the leak.
9.11
Cleaning or Replacing the Dirt Trap
9.11.1
Check and clean the dirt trap in the inlet line

The dirt trap prevents contamination of the solenoid valve and the air inlet chamber.
If problems occur during idle or during unloaded start, clean the dirt trap.
It must be cleaned every 500 service hours.
KFB052921
2
1
1 Plug
2 Strainer
9 --- 47
Maintenance
DANGER

Work carefully.
Unscrew the plug (1).
Never direct compressed air toward persons. Compressed air is a concentrated form of energy and is as such dangerous to life. Always
wear personnel protective equipment.
WARNING
Serious injury possible.

Never direct compressed air at a person!
Work carefully.
Remove the strainer (2) and clean by blowing out.

Attention!
If the strainer is very dirty or has been cleaned often it should be

replaced.
Screw the strainer (2) and plug (1) back in again.

9.11.2
Check and clean the dirt trap on the crankcase

The dirt trap prevents clogging of the oil pump.
The dirt trap must be cleaned if the compressor malfunctions during idle or during unloaded starts. It must be cleaned at the latest after 500 service hours.
KFB056821
4
1
2
3
4
3 1
locking screw
strainer
O ---ring
Dirt trap
9 --- 48
Maintenance
DANGER

Work carefully.
Unscrew the screw plug (1).
Attention!
If the dirt trap is cleaned with diesel fuel this must be done in the open
air. The appropriate regulations concerning the handling of combustible fuels must be observed.
Remove the strainer (2).

Wash out the strainer (2) with diesel fuel or by blowing out with compressed air.
Attention!
If the strainer is very dirty or has been cleaned often it should be

replaced.
Screw the strainer (2) and the plug (1) back again.
9.12
Checking the V---Belt Tension

Check the tension of the V---belt after the first two service hours and then again after a
further 24 service hours. Check the tension then again after 500 service hours.
DANGER

Work carefully.
Remove the belt guard.
Press down the V---belt with the thumb.
If the V---belt can be depressed more than 0.4 to 0.8 it must be tightened.
9 --- 49
Maintenance
0.4 ---0.8
9.13
Tensioning the V---belt(s)

DANGER

Work carefully.
Remove the belt guard
Loosen the hexagonal nuts on the motor mounts.
Slide the motor until the V---belt(s) is (are) tight again, i.e. it cannot be depressed more
than 0.4 to 0.8.
Tighten the hexagonal nuts.
Fit the belt guard again.
KFB008121
1
2
1 Hexagonal nut
2 Square ---headed bolts
9 --- 50
Maintenance
9.14
V---Belt Change
DANGER

Work carefully.
Remove the belt guard.
Loosen the hexagonal nuts on the motor mounts.
Slide the motor in the direction of the compressor block until the V---belt(s) can be removed over the motor and compressor pulley.
Place the new V---belt(s) over the motor and compressor pulley without straining it.
Slide the motor in the opposite direction until the V---belt(s) is (are) correctly tensioned.
Tighten up the hexagonal nuts.
Check the tension after the first two service hours and then again after further 24 service hours. Tighten, if necessary (see chapter 9.12).
Attention!
It is essential that all replacement belts are precisely the same length
(as a set) and absolutely oil--- proof. For this reason we recommend
that only original KAESER V--- belts are used.
V--- belts may only be replaced as a set.
Fit the belt guard again.

9.15
Testing the Safety Relief Valve

If the maximum permissible working pressure is exceeded, the safety valve opens and
blows off the excess air to protect the compressor unit and the users connected to the air
system.
Attention!
When the appropriate service hours have expired (see chapter 9.2), the
safety valve must be checked by an authorized KAESER dealer.
KFB049121
1
2
1 Knurled ring
2 Safety valve
9 --- 51
Maintenance
Safety relief valve is hot!
Attention!
Always wear ear and eye protection during the safety valve check.
During this procedure hot, pressurized air is released with a loud
noise.
Turn the knurled ring (1) on the safety valve (2) counterclockwise with the booster
package running under full load until air blows off.
Attention!
A defective safety valve must be replaced complete.

Adjustment of the safety valve setting and removal of the seal is forbidden and invalidates all liability.
9.16
Greasing the Electric Motor

Compressor motor:
The bearings are greased via nipples on the tops of the bearing endcaps.
Initial greasing of the bearings is carried out in the manufacturers works.
See chapter 1.9 for greasing periods, greasing quantity and approved bearing greases.
Clean the nipple before greasing to avoid dirt being carried in with the grease.
Grease the bearings on both ends of the shaft while the motor is running.
KGB006411
1
1
2
D ---end grease nipple

N ---end grease nipple
9 --- 52
Maintenance
9.17
Clean the nozzle

The nozzle is located in the control line to the initial pressure switch and acts as a pulsation
damper.
It must be cleaned at least every 500 operating hours.
G 1 1/2
G2
KFB056621
1
1
2
2 1
Jet
Union nut
Shut down the booster package (see chapter 8.1).
DANGER

Work carefully.
Because of the danger of injury do not direct compressed air at the
skin or other parts of the body. Take personal protection measures
(e.g. protective gloves, protective goggles).
Isolate the machine from the air main by closing the users compressed air inlet
and outlet shut ---off valves.
Unscrew fittings (2).
Unscrew the T---piece with nozzle (1).
Take out the nozzle together with the T---piece (1) and clean by blowing out with compressed air.
Attention!
If the strainer is very dirty and has already been cleaned several times
then it should be renewed.
Take out the nozzle together with the T---piece (1) and clean by blowing out.
Replace the nozzle together with the T---piece (1).
Replace the fittings (2) again.
9 --- 53
Maintenance
9.18
Check or Replace the Cylinder Heads and Valves (Compressor Block)

Check the cylinder heads, piston rings and the valves for signs of excessive wear after
3000 service hours.
Attention!
If wear is obvious on the cylinder head, piston rings or the valves,

these parts must be repaired or replaced by KAESER Service.
Have the compressor generally overhauled by your authorized KAESER distributor after
12000 service hours.
Attention!
The cylinder heads, pistons and piston rings should be inspected for
excessive wear.
To determine the level of piston ring wear, measure the ring end gap:
Gap
Required action
0.008 to 0.016
Wear normal inspect at next normal interval
over 0.02
Replace rings and inspect piston and cylinder
The cylinder head and valves should be inspected and cleaned of all varnish, carbon deposits, corrosion or rust.
Attention!
If excessive rust or corrosion are present, contact your local KAESER

distributor for corrective actions.
9 --- 54
Maintenance
9.19
Maintenance Schedule
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date
Description of work
Operating hours
Signature
9 --- 55
Spare Parts and After Sales Service

10
10.1
Service Parts and Maintenance Parts

Quantity
Part no.
6.2548.0
Air filter
1 off
6.0175.0
Check valve
1 off
8.0267.0
Solenoid control valve
1 off
7.6062.00010
Change the oil filter in the crankcase

vent
1 off
9.2147.0
Oil filter in the crankcase
1 off
6.1901.0
Dirt trap strainer in the inlet pipe
1 off
8.0501.0
Gasket
1 off
6.3488.0
Dirt trap strainer in the crankcase
1 off
8.0414.00010
Gasket
1 off
5.1517.0
Name
V---belt set
Model
Part No.
Year
Serial No.
Initial press.
psig
Displ.
MWP
psig
Voltage
Package
FLA
Hz/RPM
Phase
HP
FOR SERVICE REFER TO

EQUIPMENT NUMBER
10.2
cfm
Drive Motor
FLA
MADE IN GERMANY
Ordering Spare Parts

When ordering spare parts always state (see nameplate):
--- Compressor model
--- Serial Number
--- Year of manufacture
Important for all orders and inquiries:
Enter the data from the nameplate of the compressor unit in the nameplate shown
above.
10 --- 56

Attention!
Always order original spare parts from the compressor manufacturer

to avoid lower quality spare parts in your compressor unit.
We want to point out that maintenance parts, spare parts and accessories not supplied by
us are also not tested and authorized by us. The use of such products could change design characteristics of the compressor unit negatively and might therefore affect the safety
of the unit.
The use of such parts or accessories releases KAESER COMPRESSORS from all liabilities
and warranties for consequential damage caused by such parts or accessories.
10 --- 57
Appendix
11
Appendix
11.1
Electrical Diagram
(see following page)
11 --- 58
Appendix
11.2
Temperature Sensor Technical Specification
11.2.1
Application
PTC thermistors are used for temperature monitoring.
They are especially suitable for embedding in the windings of electric motors and transformers. PTC thermistors, in suitable housings, are also suitable for thermal protection of
other devices such as electronic sub ---assemblies, heat sinks, etc.
Function
PTC thermistors are manufactured in accordance with DIN 44081 and DIN 44082 and have
very favourable temperature sensitivity.
Electrical resistance increases sharply in the nominal response temperature range. This
resistance change can be used to switch off a power supply by using a suitable trip relay.
Electronic monitoring of temperature in the most diverse applications is also possible.
The resistance/temperature diagram shows the principle characteristics of PTC thermistors.
Temperature/resistance diagram according to DIN 44081/44082
Nominal response temperature
Resistance R ( )
11.2.2
TNF = 50 C to 200 C
in steps of 10K and 5K
4000
Specification
Resistance
Measured
voltage
Resistance in the
temperature range
---20 C to
TNF ---20 K
20 to 250
2.5 V DC
550
2.5 V DC
1330
2.5 V DC
4000
7.5 V DC
pulsed
1330
550
250
Resistance at
TNF ---5 K
Resistance at
TNF + 5 K
---20 C
Temperature
TNF ---20 K
TNF + 15 K
TNF ---5 K
TNF + 5 K
Resistance at
TNF + 15 K

High voltage insulation Ueff = 2500 V
TNF
Max. operating voltage:

30 V DC (Vmax), whereby the PTC thermistor should be operated ideally with no current
flow, or at 7.5 V DC pulsed or, even better at 2.5 V DC to avoid internal heating and
consequent shift in the nominal response temperature.
11 --- 79

S1 - 2300manual Booster

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S1 - 2300manual Booster

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SERVICE MANUAL

145 psi / 500 psi

GL---Nr.: N753 ---G---1.2300.20570 ---02 ---40 ---YD 01

Part No.: 1.2300.20570

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

Symbol and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Proper Use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

Take the compressor out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 15

Components of the Base---Mounted Booster Package . . . . . . . . . . . . . . . . . . . . . .

Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . .

Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

Prevention of thermal problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change (Compressor Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56

Service Parts and Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56

Select multi--- strand copper core wire at 40 C ambient temperature

Inlet Pressure Switch Setting

Cut ---out pressure

Range of settings for

Cut ---in pressure

Safety Relief Valve Setting

Ensure that the compressor package is level.

Max. height above sea level at place of installation . . . . . . 3000 ft.

Greasing the Electrical Motor

part No.: 9.0915.0

part No.: 6.3234.0

Replace the compressor motor bearings:

ISO 100 Semi---Synthetic

ISO 100 Synthetic Lubricant

Oil changes may need to be more frequent depending on ambient conditions.

ISO 46 Food Grade

First Oil Change

Oil changes may need to be more frequent depending on ambient conditions.

High Nitrile Buna N

Oil Resistant Alkyd

Polycarbonate bowls can be etched by any synthetic lubricant.

Symbol and Identification

Here are consequences of ignoring the warning notice.

Consequences of ignoring the warning

death or severe injury or serious damage to

death or severe injury or serious damage to

light injury or slight damage possible

This symbol is placed before all references to safety where danger to

This symbol is placed by text where considerable attention must be

Miscellaneous notices and symbols

This symbol indicates actions to be carried out by the user.

This bullet identifies listings.

General Safety Precautions

Any alterations or reconstruction carried out without the prior written

No welding, heat--- treatment or mechanical work may be carried out on

Safety devices may not be modified or deactivated.

Additional Safety Precautions

Comply with the following:

Electrical Power Supply

The main power supply and overcurrent protection must be installed

Proper Use of the Compressor

The equipment may only be used or serviced by authorized and

Handling the Document

Pass the manual on the the next owner/user of the machine.