BB53C EMR#2182794 Manual

SERVICE MANUAL
Rotary Blowers
Model: BB C pr
No.: 9_5757_05E
Manufacturer:
KAESER KOMPRESSOREN GmbH

PO Box 2143 S 96410 Coburg S GERMANY S Tel. +49 9561 6400 S Fax. +49 9561 640130
http://www.kaeser.com
Contents
Chapter --- page
1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Handling the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Further Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Symbols and Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4.1 Warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4.2 Other notices and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
2 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

2.1 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.2 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.3 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.3.1 BB 52 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.3.2 BB 53 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.3.3 BB 68 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.3.4 BB 88 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 10
2.4 Motors and Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 12
2.4.1 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 12
2.4.2 Fan motor sound enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 12
2.5 Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 13
2.5.1 BB 52 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 14
2.5.2 BB 53 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 16
2.5.3 BB 68 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 18
2.5.4 BB 88 C pr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 20
2.6 Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
2.6.1 Recommended lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
2.6.2 Lubricating oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
2.7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
2.7.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
2.7.2 Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 26

3.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 26
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 26
3.3 User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 27
3.3.1 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 27
3.4 Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 28
3.4.1 Awareness of danger sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 28
3.4.2 Safe machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 30
3.4.3 Organising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 31
3.4.4 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 31
3.5 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 32
3.6 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 32
3.7 In Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33
3.7.1 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33
3.7.2 Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33
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3.8 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33

3.9 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 34
4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35

4.1 Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35
4.1.1 Blower block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35
4.1.2 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 36
4.1.3 Sound enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 37
4.1.4 Blowoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 38
4.1.5 Pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 39
4.1.6 Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 39
4.2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 40
5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41

5.1 Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41
5.2 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41
5.2.1 Place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41
5.2.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 42
6.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 42
6.2 Report any Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 42
6.3 Safety devices installed by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 42
6.4 Making the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 43
6.5 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 43
6.6 Anchoring the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 43
7 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44

7.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.2 To be Observed Before Every Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.3 Check Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45
7.4 Checking Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 47
8.1 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 47
8.1.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 47
8.1.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 47
8.2 On, Off and Speed---change Switching of a Two---speed Motor . . . . . . . . . . 8 --- 47
8.2.1 Operating in low speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 47
8.2.2 Operating in two speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 48
8.3 Fan function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 48
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9 Fault Finding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49

9.1 Abnormal noise when running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.2 Block too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.3 Lubricating oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.4 Reduced air inlet flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.5 Black film on the oil sight glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
9.6 Water in the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
9.7 Sound enclosure overheating (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
9.8 Other Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.2.1 Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.3 Tensioning and Changing the V ---belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.3.1 Check the V ---belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.3.2 Changing the V ---belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.4 Checking and Topping up the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.4.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.4.2 Top up with oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.5 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
10.6 Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
10.6.1 Maintenance indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
10.6.2 Change the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.7 Checking the blowoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.8 Motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.8.1 Drive motor with re---greasing facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.8.2 Drive motor without re---greasing facility . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.8.3 Sound enclosure extractor motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.9 Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 60
11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 61

11.1 Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 61
11.2 Ordering Consumable Parts and Operating Materials . . . . . . . . . . . . . . . . . . 11 --- 61
11.3 Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.4 Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.5 Spare Parts for Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.6 Declaration of Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67
12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . . 12 --- 69

12.1 De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69
12.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69
12.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69
12.4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 70
12.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 71
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13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 72
13.1 Design Data (diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 72
13.1.1 Diagram OMEGA 21 PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 73
13.2 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 76
13.2.1 Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 76
13.2.2 Dimensional drawing of machine without the optional sound enclosure 13 --- 81
13.3 Electrical Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 86
13.3.1 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 86
13.3.2 Sound enclosure extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 87
13.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 89
13.4.1 Check plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 89
13.4.2 Unloaded start valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
13.4.3 Starting and regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 92
13.4.4 Solenoid starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 94
13.4.5 Temperature gauge switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 96
13.4.6 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 98
13.4.7 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 99
13.4.8 Pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 100
13.4.9 Pressure differential switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 102
iv
Directory of Illustrations
Chapter --- page
Fig. 1 Location of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33

Fig. 2 Blower block overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35
Fig. 3 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35
Fig. 4 Drawing air from the surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 36
Fig. 5 Sound enclosure overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 37
Fig. 6 Blowoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 38
Fig. 7 Location of the pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 39
Fig. 8 Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 39
Fig. 9 Fitting the split cuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 43
Fig. 10 Belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
Fig. 11 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
Fig. 12 Topping up with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
Fig. 13 Drain the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
Fig. 14 Air filter maintenance indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
Fig. 15 Air filter maintenance indicator (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
Fig. 16 Change the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Fig. 17 Transport by fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 70
Fig. 18 Transport by lifting cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 71
Fig. 19 Star connection for a 3---phase motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 86
Fig. 20 Delta connection for a 3---phase motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 87
Fig. 21 Extractor motor star---delta connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 87
Fig. 22 Extractor motor single---phase connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 88
Fig. 23 Check plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 89
Fig. 24 Unloaded start valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
Fig. 25 Unloaded start valve diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 91
Fig. 26 Starting and regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 92
Fig. 27 Starting and regulating valve diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 93
Fig. 28 Solenoid starting valve AFM 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 94
Fig. 29 Solenoid starting valve AFM 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 95
Fig. 30 Bearing temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 96
Fig. 31 Temperature gauge connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 97
Fig. 32 Temperature gauge switch dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 97
Fig. 33 Thermostat electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 98
Fig. 34 Thermostat dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 99
Fig. 35 Pressure switch connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 99
Fig. 36 Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 100
Fig. 37 Pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 100
Fig. 38 Terminal assignment pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 101
Fig. 39 Pressure differential switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 102
Fig. 40 Pressure differential switch connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 103
Fig. 41 Switch function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 103
v
Table Directory
Chapter --- page
Tab. 1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

Tab. 2 Machine weight without motor (guide value) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 3 Motor weight (guide value) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 4 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 5 Sound pressure level BB 52 C pr (guide value at 50 Hz / 400 V) . . . . . . . . . . 2 --- 4
Tab. 13 Drive motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 12
Tab. 14 Fan motor data, 3---ph, 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 12
Tab. 18 Design data BB 52 C pr (guide value at 50 Hz / 400 V) . . . . . . . . . . . . . . . . . . 2 --- 14
Tab. 26 Recommended lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
Tab. 27 Lubricating oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 22
Tab. 28 Current draw 230V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 23
Tab. 29 Power supply data for star---delta starting 230V/3/50Hz . . . . . . . . . . . . . . . . . . 2 --- 23
Tab. 30 Power supply data for direct online starting 230V/3/50Hz . . . . . . . . . . . . . . . . 2 --- 23
Tab. 43 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 31
Tab. 44 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 32
Tab. 45 Blowoff valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 38
Tab. 46 Compensator dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 40
vi
Table Directory
Chapter --- page
Tab. 47 Installation conditions checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45

Tab. 48 Abnormal noises and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
Tab. 49 Block becomes too hot --- remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
Tab. 50 Oil leakage and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
Tab. 51 Reduced inlet flow and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
Tab. 52 Black film on the oil sight glasses and remedies . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
Tab. 53 Water in the oil and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
Tab. 54 Sound enclosure overheating and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
Tab. 55 Other faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
Tab. 56 Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
Tab. 57 Logged maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 60
Tab. 58 Consumable parts, machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 61
Tab. 59 Lubricating oil overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 61
Tab. 60 Preserving oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 70
Tab. 61 Check plate dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 89
Tab. 62 Unloaded start valve technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
Tab. 63 Unloaded start valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
Tab. 64 Starting and regulating valve technical specifications . . . . . . . . . . . . . . . . . . . . 13 --- 92
Tab. 65 Starting and regulating valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 92
Tab. 66 Solenoid starting valve AFM 4 technical specification . . . . . . . . . . . . . . . . . . . . 13 --- 94
Tab. 67 Solenoid starting valve AFM 4 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 94
Tab. 68 Solenoid starting valve AFM 5 technical specification . . . . . . . . . . . . . . . . . . . . 13 --- 95
Tab. 69 Solenoid starting valve AFM 5 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 95
Tab. 70 Temperature gauge switch technical specification . . . . . . . . . . . . . . . . . . . . . . . 13 --- 96
Tab. 71 Thermostat technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 98
Tab. 72 Pressure switch technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 99
Tab. 73 Pressure transducer technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 100
Tab. 74 Trouble shooting pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 101
Tab. 75 Pressure diferential switch technical specification . . . . . . . . . . . . . . . . . . . . . . . 13 --- 102
vii
Regarding this Document
1 Regarding this Document
1.1 Handling the Document

The service manual is part of the machine.
. Keep the service manual in a safe place throughout the life of the machine.
. Pass the manual on the next owner/user of the machine.
. Ensure that all amendments are entered in the manual.
. Enter details from the machine nameplate in the table in chapter 2 ’Technical Specifica-
tions’.
1.2 Further Documents

Included with this Service Manual are documents intended to assist in safe and sure oper-
ation of the machine:
D manufacturer’s declaration in accordance with applicable directives
D Design data sheet
. Make sure all documents are to hand and observe the instructions contained in them.
Missing documents can be requested from KAESER.
Always quote the data on the nameplate.
1.3 Copyright
This service manual is copyright protected. Please contact KAESER if you have any queries
regarding use and copying of the documentation. We will gladly help you with the appropri-
ate use of the information.
1.4 Symbols and Identifications
1.4.1 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 ig-
noring the notice.
. Always read and 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 threat- Death or severe injury may result
ening danger
WARNING Warns of possible threat- Severe injury or serious damage to the ma-
ening danger chine is possible
CAUTION Warns of a possibly dan- Light injury or slight damage possible
gerous situation
1 --- 1
Regarding this Document
1.4.2 Other notices and symbols

. Here is a task to be carried out.
This symbol identifies environmental protection measures.
This symbol refers to particularly important information.
1 --- 2
Technical Specification
2 Technical Specification
The model designation and important technical information is to be found on the machine
nameplate. The nameplate is found on the machine frame.
Please enter here the data from the nameplate:
Model
Material (part) no.
Serial No.
Year of manufacture
Delivery
Max. final pressure (a)
Max. pressure differential
Rated power
Rotational speed
Tab. 1 Nameplate
2.1 Weight
The weight given is for the machine in standard design. The actual weight depends on indi-
vidual equipment and accessories.
Model Machine without motor
without sound enclosure with sound enclosure
[kg] [kg]
BB 52 C pr 80 150
BB 53 C pr 110 230
BB 68 C pr 115 235
BB 88 C pr 121 241
Tab. 2 Machine weight without motor (guide value)
Power Frame size Motor

[kW] Cast iron Aluminium
[kg]* [kg]*
1.5 90/100 20 20
2.2 100 23 22
3 100 32 24
4 112 42 34
5.5 132 60 42
7.5 132 65 56
11 132 79 67
15 132 --- 80
* Guide value, actual weight can vary according to manufacturer
Tab. 3 Motor weight (guide value)
2.2 Ambient Conditions

Ambient temperature [˚C] ---15 --- +40
Inlet air temperature [˚C] ---15 --- +40
Tab. 4 Ambient Conditions
2 --- 3
2.3 Sound Pressure Level

Operational state:
D under load at rated speed, rated delivery and rated pressure.
Measuring conditions:
D Free---field measurement to DIN EN ISO 2151 at 1 m distance, within ± 3 dB(A), with
acoustic insulated pipelines
Symbols used in the sound pressure level table:
∆p Pressure differential
nk Blower block speed
Lp [A] Sound pressure level
2.3.1 BB 52 C pr
Guide values for 50 Hz / 400 V
∆p nk
1330 1760 2470 3630 4270 4850 5480 6170
[mbar] [rpm]
Lp [A]
without en- 77 77 77 80 81 83 84 86
300
closure
with enclosure 72 72 72 72 72 72 72 74
Lp [A]
without en- 77 77 78 82 84 85 86 87
400
closure
with enclosure 72 72 72 72 72 73 74 75
Lp [A]
without en- 81 83 86 86 87 87 88
500
closure ---
with enclosure 72 72 74 74 75 75 76
Lp [A]
without en- 84 86 87 88 88 89
600
closure --- ---
with enclosure 72 74 75 76 76 77
Lp [A]
without en- 83 86 87 87 88
700
closure --- --- ---
with enclosure 72 74 75 75 76
Lp [A]
without en- 86 87 88
800
closure --- --- --- --- ---
with enclosure 74 75 76
Lp [A]
without en- 87 88
900
closure --- --- --- --- --- ---
with enclosure 75 76
Lp [A]
without en- 90
1000
closure --- --- --- --- --- --- ---
with enclosure 78
Tab. 5 Sound pressure level BB 52 C pr (guide value at 50 Hz / 400 V)
2 --- 4
Guide values at 60 Hz / 400 V
∆p nk
1310 1740 2120 2965 3490 4355 5125 5820
[mbar] [rpm]
Lp [A]
without en- 77 77 77 78 79 81 84 85
300
closure
with enclosure 72 72 72 72 72 72 72 73
Lp [A]
without en- 77 77 77 80 82 84 86 87
400
closure
with enclosure 72 72 72 72 72 72 74 75
Lp [A]
without en- 81 82 84 85 86 87 88
500
closure ---
with enclosure 72 72 72 73 74 75 76
Lp [A]
without en- 83 85 86 87 88 89
600
closure --- ---
Lp [A]
without en- 85 85 87 88 88
700
closure --- --- ---
Lp [A]
without en- 85 85 87 88
800
closure --- --- --- ---
with enclosure 73 73 75 76
Lp [A]
without en- 86 88
900
closure --- --- --- --- --- ---
2 --- 5
2.3.2 BB 53 C pr
∆p nk
2600 2910 3430 3840 4270 4850 5480 6170
[mbar] [rpm]
Lp [A]
300 without enclosure 74 74 76 77 78 80 82 85
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 70
Lp [A]
with enclosure 69 69 69 69 69 69 69 71
Lp [A]
with enclosure 69 69 69 69 69 69 69 72
Lp [A]
900 without enclosure --- --- 77 79 80 81 83 85
Lp [A]
1000 without enclosure --- --- --- --- 85 87 89 92
2 --- 6
∆p nk
2510 2965 3490 3910 4355 4610 5435 5820
[mbar] [rpm]
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 71
Lp [A]
with enclosure 69 69 69 69 69 69 70 72
Lp [A]
900 without enclosure --- --- 79 80 81 82 84 85
Lp [A]
2 --- 7
2.3.3 BB 68 C pr
∆p nk
2470 2750 3260 3630 4050 4530 5180 5800
[mbar] [rpm]
Lp [A]
without en- 76 77 78 79 81 82 84 86
300
closure
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
without en- 77 78 79 80 82 83 85 87
400
closure
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
without en- 78 79 80 81 83 84 86 88
500
closure
with enclosure 69 69 69 69 69 69 69 70
Lp [A]
without en- 78 79 80 81 83 84 86 88
600
closure
with enclosure 69 69 69 69 69 69 69 70
Lp [A]
without en- 78 79 80 82 83 85 87 89
700
closure
with enclosure 69 69 69 69 69 69 69 70
Lp [A]
without en- 81 83 84 86 88 90
800
closure --- ---
Lp [A]
without en- 84 85 87 89 91
900
closure --- --- ---
Lp [A]
without en- 86 88 90 92
1000
closure --- --- --- ---
2 --- 8
∆p nk
2510 2965 3490 3910 4355 4610 5125 5435
[mbar] [rpm]
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 69
Lp [A]
with enclosure 69 69 69 69 69 69 69 70
Lp [A]
800 without enclosure --- 80 82 84 85 86 88 89
with enclosure 69 69 69 69 69 70 70
Lp [A]
900 without enclosure --- --- --- 85 86 87 89 90
Lp [A]
2 --- 9
2.3.4 BB 88 C pr
∆p nk
2470 2750 3260 3630 4050 4530 5180 5800
[mbar] [rpm]
Lp [A]
without en- 77 77 79 80 82 84 88 91
300
closure
with enclosure 69 69 69 69 69 69 69 72
Lp [A]
without en- 78 78 80 81 83 85 88 92
400
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 77 77 79 80 82 84 88 91
500
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 78 79 81 82 84 86 90 94
600
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 79 80 81 83 85 87 91 95
700
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 80 82 84 86 89 92 96
800
closure ---
with enclosure 69 69 69 69 70 70 70
Lp [A]
without en- 85 87 90 94
900
closure --- --- --- ---
Lp [A]
without en- 87 90
1000
closure --- --- --- --- --- ---
2 --- 10
∆p nk
2510 2965 3490 3910 4355 4610 5125 5435
[mbar] [min ---1]
Lp [A]
without en- 77 78 80 81 83 84 88 89
300
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 78 79 81 82 84 85 88 90
400
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 77 78 80 81 83 84 88 89
500
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 78 79 82 83 86 87 90 92
600
closure
with enclosure 69 69 69 69 69 69 70 70
Lp [A]
without en- 79 80 82 84 86 88 91 93
700
closure
with enclosure 69 69 69 69 69 70 70 70
Lp [A]
without en- 81 83 85 88 89 92 94
800
closure ---
with enclosure 69 69 69 70 70 70 70
Lp [A]
without en- 84 86 89 90 94 96
900
closure --- ---
Lp [A]
without en- 86 89 90
1000
closure --- --- --- --- ---
with enclosure 69 70 70
2 --- 11
2.4 Motors and Capacity
2.4.1 Drive motor
Rated power [kW] * 1.5 --- 15

Synchronous speed [rpm] (50 Hz) 3000
Synchronous speed [rpm] (60 Hz) 3600
Enclosure protection IP 55
* see motor nameplate
Tab. 13 Drive motor data
2.4.2 Fan motor sound enclosure

Nominal delivery: 450 --- 500 m3/h
3---phase, 50 Hz
Rated voltage [V] 230/400 230/400 290/500

Rated power ±10% [kW] 0.08 0.18 0.08
Current draw ±10% [A] 0.55/0.32 0.87/0.51 0.46/0.27
Enclosure protection IP 55 IP 65 IP 55
Tab. 14 Fan motor data, 3 ---ph, 50 Hz
3---phase, 60 Hz
Rated voltage [V] 208/360 230/400 266/460 277/480 333/575

Rated power ±10% [kW] 0.08 0.08 0.09 0.21 0.08
Current draw ±10% [A] 0.61/0.35 0.55/0.32 0.55/0.32 1.07/0.62 0.36/0.21
Enclosure protection IP 55 IP 55 IP 55 IP 55 IP 55
1---phase, 50 Hz
Rated voltage [V] 230

Rated power ±10% [kW] 0.08
Current draw ±10% [A] 0.6
1---phase, 60 Hz
Rated voltage [V] 115 230

Rated power ±10% [kW] 0.08 0.08
Current draw ±10% [A] 1.35 0.6
Enclosure protection IP 55 IP 55
2 --- 12
2.5 Design Data

Design data for pressure operation: p1= 1013 mbar (a), t1= 20 ˚C, medium --- air
(1.2 kg/m3).
Delivery and drive power to ISO 1217, part 1, annex C.
Customer---specific design data sheets are included in the service manual on delivery of the
machine.
Symbols used in the technical specification table:
Q1 Delivery
∆p Pressure differential
nk Blower block speed
∆t Temperature differential
PK Blower block drive power
Pmot Drive motor coupling power
2 --- 13
2.5.1 BB 52 C pr
∆p nk
1330 1760 2470 3630 4270 4850 5480 6170
[mbar] [rpm]
Q1 [m3/min] 0.59 0.96 1.58 2.58 3.13 3.63 4.18 4.77
∆t [K] 48 39 34 30 29 29 28 28
300
PK [kW] 0.93 1.14 1.50 2.13 2.50 2.85 3.24 3.69
Pmot [kW] 1.5 1.5 2.2 3 3 4 4 5.5
Q1 [m3/min] 0.50 0.88 1.49 2.49 3.04 3.55 4.09 4.69
∆t [K] 75 57 47 42 40 39 38 38
400
PK [kW] 1.12 1.39 1.85 2.65 3.12 3.55 4.03 4.58
Pmot [kW] 1.5 2.2 2.2 3 4 4 5.5 5.5
3
Q1 [m /min] --- 0.80 1.41 2.42 2.97 3.47 4.01 4.61
∆t [K] --- 79 62 54 51 50 49 48
500
PK [kW] --- 1.64 2.21 3.18 3.73 4.25 4.82 5.47
Pmot [kW] --- 2.2 3 4 5.5 5.5 5.5 7.5
3
Q1 [m /min] --- --- 1.34 2.35 2.90 3.40 3.94 4.54
∆t [K] --- --- 79 66 63 61 60 58
600
PK [kW] --- --- 2.57 3.70 4.35 4.94 5.61 6.36
Pmot [kW] --- --- 3 5.5 5.5 5.5 7.5 7.5
Q1 [m3/min] --- --- 1.28 2.28 2.84 3.34 3.88 ---
∆t [K] --- --- 96 79 75 73 71 ---
700
PK [kW] --- --- 2.92 4.22 4.96 5.64 6.40 ---
Pmot [kW] --- --- 4 5.5 5.5 7.5 7.5 ---
3
Q1 [m /min] --- --- --- 2.22 2.78 3.28 --- ---
∆t [K] --- --- --- 93 88 84 --- ---
800
PK [kW] --- --- --- 4.74 5.57 6.34 --- ---
Pmot [kW] --- --- --- 5.5 7.5 7.5 --- ---
Q1 [m3/min] --- --- --- 2.17 2.72 --- --- ---
∆t [K] --- --- --- 108 101 --- --- ---
900
PK [kW] --- --- --- 5.27 6.19 --- --- ---
Pmot [kW] --- --- --- 7.5 7.5 --- --- ---
3
Q1 [m /min] --- --- --- --- 2.67 --- --- ---
∆t [K] --- --- --- --- 114 --- --- ---
1000
PK [kW] --- --- --- --- 6.80 --- --- ---
Pmot [kW] --- --- --- --- 7.5 --- --- ---
Tab. 18 Design data BB 52 C pr (guide value at 50 Hz / 400 V)
2 --- 14
∆p nk
1310 1740 2120 2965 3490 4355 5125 5820
[mbar] [rpm]
Q1 [m3/min] 0.57 0.95 1.27 2.00 2.46 3.20 3.87 4.47
∆t [K] 49 39 36 32 30 29 28 28
300
PK [kW] 0.92 1.13 1.32 1.76 2.05 2.55 3.02 3.46
Pmot [kW] 1.5 1.5 1.5 2.2 3 3 4 4
Q1 [m3/min] 0.49 0.86 1.19 1.92 2.37 3.12 3.78 4.38
∆t [K] 77 58 51 44 42 40 39 38
400
PK [kW] 1.11 1.38 1.62 2.19 2.55 3.18 3.76 4.30
Pmot [kW] 1.5 2.2 2.2 3 3 4 5.5 5.5
3
Q1 [m /min] --- 0.78 1.11 1.84 2.29 3.04 3.71 4.31
∆t [K] --- 79 68 57 54 51 49 48
500
PK [kW] --- 1.63 1.93 2.62 3.06 3.81 4.50 5.14
Pmot [kW] --- 2.2 2.2 3 4 5.5 5.5 7.5
3
Q1 [m /min] --- --- 1.04 1.77 2.23 2.97 3.64 4.24
∆t [K] --- --- 87 72 67 63 60 59
600
PK [kW] --- --- 2.23 3.04 3.56 4.43 5.23 5.97
Pmot [kW] --- --- 3 4 4 5.5 7.5 7.5
Q1 [m3/min] --- --- --- 1.71 2.16 2.91 3.57 4.17
∆t [K] --- --- --- 87 81 75 72 70
700
PK [kW] --- --- --- 3.47 4.06 5.06 5.97 6.81
Pmot [kW] --- --- --- 4 5.5 5.5 7.5 7.5
3
Q1 [m /min] --- --- --- 1.65 2.10 2.85 3.52 ---
∆t [K] --- --- --- 100 95 87 83 ---
800
PK [kW] --- --- --- 3.90 4.56 5.69 6.71 ---
Pmot [kW] --- --- --- 5.5 5.5 7.5 7.5 ---
Q1 [m3/min] --- --- --- --- 2.05 2.80 --- ---
∆t [K] --- --- --- --- 109 100 --- ---
900
PK [kW] --- --- --- --- 5.07 6.31 --- ---
Pmot [kW] --- --- --- --- 5.5 7.5 --- ---
2 --- 15
2.5.2 BB 53 C pr
∆p nk
2600 2910 3430 3840 4270 4850 5480 6170
[mbar] [rpm]
Q1 [m3/min] 1.69 1.96 2.40 2.76 3.13 3.63 4,18 4,77
∆t [K] 33 32 31 30 29 29 28 28
300
PK [kW] 1.57 1.73 2.02 2.25 2.50 2.85 3.24 3.69
Pmot [kW] 2.2 2.2 3 3 3 4 4 5.5
Q1 [m3/min] 1.60 1.87 2.32 2.67 3.04 3.55 4.09 4.69
∆t [K] 46 44 42 41 40 39 38 38
400
PK [kW] 1.94 2.15 2.51 2.80 3.12 3.55 4.03 4.58
Pmot [kW] 2.2 3 3 4 4 4 5.5 5.5
3
Q1 [m /min] 1.53 1.79 2.24 2.60 2.97 3.47 4.01 4.61
∆t [K] 61 58 55 53 51 50 49 48
500
PK [kW] 2.32 2.57 3.01 3.36 3.73 4.25 4.82 5.47
Pmot [kW] 3 3 4 4 5.5 5.5 5.5 7.5
3
Q1 [m /min] 1.46 1.72 2.17 2.53 2.90 3.40 3.94 4.54
∆t [K] 76 72 68 65 63 61 60 58
600
PK [kW] 2.69 2.99 3.50 3.91 4.35 4.94 5.61 6.36
Pmot [kW] 3 4 4 5.5 5.5 5.5 7.5 7.5
Q1 [m3/min] 1.39 1.66 2.11 2.46 2.84 3.34 3.88 4.48
∆t [K] 93 88 81 78 75 73 71 69
700
PK [kW] 3.06 3.41 3.99 4.46 4.96 5.64 6.40 7.24
Pmot [kW] 4 4 5.5 5.5 5.5 7.5 7.5 11
3
Q1 [m /min] 1.33 1.60 2.05 2.41 2.78 3.28 3.82 4.42
∆t [K] 111 104 95 91 88 84 82 80
800
PK [kW] 3.44 3.83 4.49 5.01 5.57 6.34 7.19 8.13
Pmot [kW] 4 5.5 5.5 5.5 7.5 7.5 11 11
Q1 [m3/min] --- --- 2.00 2.35 2.72 3.22 3.77 4.36
∆t [K] --- --- 110 105 101 97 93 91
900
PK [kW] --- --- 4.98 5.57 6.19 7.04 7.98 9.02
Pmot [kW] --- --- 5.5 7.5 7.5 11 11 11
3
Q1 [m /min] --- --- --- --- 2.67 3.17 3.71 4.31
∆t [K] --- --- --- --- 114 109 105 102
1000
PK [kW] --- --- --- --- 6.80 7.74 8.77 9.91
Pmot [kW] --- --- --- --- 7.5 11 11 11
2 --- 16
∆p nk
2510 2965 3490 3910 4355 4610 5435 5820
[mbar] [rpm]
Q1 [m3/min] 1.61 2.00 2.46 2.82 3.20 3.42 4.14 4.47
∆t [K] 33 32 30 30 29 29 28 28
300
PK [kW] 1.52 1.76 2.05 2.29 2.55 2.70 3.21 3.46
Pmot [kW] 2.2 2.2 3 3 3 4 4 4
Q1 [m3/min] 1.52 1.92 2.37 2.73 3.12 3.34 4.05 4.38
∆t [K] 47 44 42 41 40 39 38 38
400
PK [kW] 1.88 2.19 2.55 2.85 3.18 3.37 4.00 4.30
Pmot [kW] 2.2 3 3 4 4 4 5.5 5.5
3
Q1 [m /min] 1.45 1.84 2.29 2.66 3.04 3.26 3.97 4.31
∆t [K] 62 57 54 53 51 60 49 48
500
PK [kW] 2.24 2.62 3.06 3.42 3.81 4.03 4.78 5.14
Pmot [kW] 3 3 4 4 5.5 5.5 5.5 7.5
3
Q1 [m /min] 1.38 1.77 2.23 2.59 2.97 3.19 3.91 4.24
∆t [K] 78 72 67 65 63 62 60 59
600
PK [kW] 2.60 3.04 3.56 3.98 4.43 4.69 5.56 5.97
Pmot [kW] 3 4 4 5.5 5.5 5.5 7.5 7.5
Q1 [m3/min] 1.32 1.71 2.16 2.53 2.91 3.13 3.84 4.17
∆t [K] 95 87 81 77 75 74 71 70
700
PK [kW] 2.96 3.47 4.06 4.54 5.06 5.36 6.34 6.81
Pmot [kW] 4 4 5.5 5.5 5.5 7.5 7.5 7.5
3
Q1 [m /min] 1.26 1.65 2.10 2.47 2.85 3.07 3.78 4.12
∆t [K] 114 103 95 91 87 86 82 81
800
PK [kW] 3.33 3.90 4.56 5.11 5.69 6.02 7.13 7.65
Pmot [kW] 4 5.5 5.5 5.5 7.5 7.5 11 11
Q1 [m3/min] --- --- 2.05 2.41 2.80 3.02 3.73 4.06
∆t [K] --- --- 109 104 100 98 94 92
900
PK [kW] --- --- 5.07 5.67 6.31 6.69 7.91 8.49
Pmot [kW] --- --- 5.5 7.5 7.5 7.5 11 11
3
Q1 [m /min] --- --- --- --- 2.74 2.96 3.68 4.01
∆t [K] --- --- --- --- 113 111 106 104
1000
PK [kW] --- --- --- --- 6.94 7.35 8.69 9.33
Pmot [kW] --- --- --- --- 7.5 11 11 11
2 --- 17
2.5.3 BB 68 C pr
∆p nk
2470 2750 3260 3630 4050 4530 5180 5800
[mbar] [rpm]
Q1 [m3/min] 2.10 2.42 3.00 3.42 3.90 4.44 5.18 5.89
∆t [K] 33 32 31 30 29 29 28 28
300
PK [kW] 1.86 2.05 2.40 2.66 2.97 3.33 3.82 4.32
Pmot [kW] 2.2 3 3 4 4 4 5.5 5.5
Q1 [m3/min] 1.99 2.31 2.89 3.31 3.79 4.33 5.07 5.78
∆t [K] 47 45 43 41 40 39 38 38
400
PK [kW] 2.33 2.57 3.02 3.35 3.74 4.18 4.81 5.42
Pmot [kW] 3 3 4 4 5.5 5.5 5.5 7.5
3
Q1 [m /min] 1.89 2.21 2.79 3.21 3.69 4.23 4.97 5.68
∆t [K] 62 59 55 53 52 50 49 48
500
PK [kW] 2.80 3.09 3.64 4.04 4.50 5.04 5.79 6.52
Pmot [kW] 4 4 4 5.5 5.5 7.5 7.5 7.5
3
Q1 [m /min] 1.80 2.12 2.70 3.12 3.60 4.15 4.89 5.59
∆t [K] 77 73 68 66 64 62 60 59
600
PK [kW] 3.26 3.61 4.26 4.73 5.27 5.90 6.77 7.62
Pmot [kW] 4 4 5.5 5.5 7.5 7.5 7.5 11
Q1 [m3/min] 1.72 2.04 2.62 3.04 3.52 4.07 4.81 5.51
∆t [K] 95 89 82 79 76 73 71 69
700
PK [kW] 3.73 4.14 4.88 5.42 6.04 6.76 7.76 8.72
Pmot [kW] 5.5 5.5 5.5 7.5 7.5 7.5 11 11
3
Q1 [m /min] --- --- 2.54 2.97 3.44 3.99 4.73 5.44
∆t [K] --- --- 96 92 89 85 82 80
800
PK [kW] --- --- 5.49 6.11 6.81 7.62 8.74 9.82
Pmot [kW] --- --- 7.5 7.5 7.5 11 11 11
Q1 [m3/min] --- --- --- 2.89 3.37 3.92 4.66 5.37
∆t [K] --- --- --- 106 102 98 94 92
900
PK [kW] --- --- --- 6.80 7.58 8.48 9.72 10.90
Pmot [kW] --- --- --- 7.5 11 11 11 15
3
Q1 [m /min] --- --- --- --- 3.31 3.85 4.59 5.30
∆t [K] --- --- --- --- 115 111 106 103
1000
PK [kW] --- --- --- --- 8.35 9.34 10.70 12.00
Pmot [kW] --- --- --- --- 11 11 15 15
2 --- 18
∆p nk
2510 2965 3490 3910 4355 4610 5125 5435
[mbar] [rpm]
Q1 [m3/min] 2.14 2.66 3.26 3.74 4.24 4.53 5.12 5.47
∆t [K] 33 31 30 30 29 29 28 28
300
PK [kW] 1.89 2.20 2.56 2.87 3.19 3.39 3.78 4.02
Pmot [kW] 2.2 3 3 4 4 4 5.5 5.5
Q1 [m3/min] 2.03 2.55 3.15 3.63 4.13 4.42 5.01 5.36
∆t [K] 46 44 42 41 40 39 39 38
400
PK [kW] 2.36 2.76 3.23 3.61 4.02 4.26 4.75 5.06
Pmot [kW] 3 4 4 5.5 5.5 5.5 5.5 7.5
3
Q1 [m /min] 1.93 2.45 3.05 3.53 4.04 4.33 4.91 5.27
∆t [K] 61 57 54 52 51 50 49 49
500
PK [kW] 2.84 3.32 3.89 4.35 4.85 5.14 5.73 6.09
Pmot [kW] 4 4 5.5 5.5 5.5 7.5 7.5 7.5
3
Q1 [m /min] 1.85 2.36 2.96 3.44 3.95 4.24 4.82 5.18
∆t [K] 77 71 67 64 62 61 60 59
600
PK [kW] 3.31 3.88 4.55 5.09 5.67 6.01 6.70 7.12
Pmot [kW] 4 5.5 5.5 7.5 7.5 7.5 7.5 11
Q1 [m3/min] 1.77 2.28 2.88 3.46 3.87 4.16 4.74 5.10
∆t [K] 94 86 80 77 74 73 71 70
700
PK [kW] 3.79 4.45 5.21 5.83 6.50 6.88 7.67 8.15
Pmot [kW] 5.5 5.5 7.5 7.5 7.5 7.5 11 11
3
Q1 [m /min] --- 2.21 2.81 3.28 3.79 4.08 4.67 5.02
∆t [K] --- 101 94 90 86 85 83 81
800
PK [kW] --- 5.01 5.87 6.58 7.33 7.76 8.64 9.18
Pmot [kW] --- 5.5 7.5 7.5 11 11 11 11
Q1 [m3/min] --- --- --- 3.21 3.72 4.01 4.60 4.95
∆t [K] --- --- --- 103 99 97 94 93
900
PK [kW] --- --- --- 7.32 8.15 8.63 9.62 10.20
Pmot [kW] --- --- --- 11 11 11 11 11
3
Q1 [m /min] --- --- --- --- 3.65 3.94 4.53 4.88
∆t [K] --- --- --- --- 112 110 106 105
1000
PK [kW] --- --- --- --- 8.98 9.51 10.60 11.20
Pmot [kW] --- --- --- --- 11 11 15 15
2 --- 19
2.5.4 BB 88 C pr
∆p nk
2470 2750 3260 3630 4050 4530 5180 5800
[mbar] [rpm]
Q1 [m3/min] 2.98 3.42 4.22 4.80 5.46 6.21 7.23 8.21
∆t [K] 32 31 30 29 29 28 28 28
300
PK [kW] 2.42 2.67 3.14 3.49 3.90 4.37 5.03 5.67
Pmot [kW] 3 4 4 4 5,5 5,5 7,5 7,5
Q1 [m3/min] 2.84 3.28 4.08 4.66 5.32 6.07 7.09 8.07
∆t [K] 45 44 41 40 40 39 38 37
400
PK [kW] 3.06 3.39 4.00 4.44 4,96 5.56 6.38 7.19
Pmot [kW] 4 4 5.5 5.5 7.5 7.5 7.5 11
3
Q1 [m /min] 2.71 3.15 3.96 4.54 5.20 5.95 6.97 7.94
∆t [K] 59 57 53 52 51 49 48 47
500
PK [kW] 3.71 4.11 4.85 5.39 6.02 6.74 7.74 8.71
Pmot [kW] 5.5 5.5 5.5 7.5 7.5 7.5 11 11
3
Q1 [m /min] 2.60 3.04 3.84 4.43 5.09 5.84 6.86 7.83
∆t [K] 74 70 66 64 62 60 59 58
600
PK [kW] 4.36 4.83 5.70 6.34 7.08 7.93 9.10 10.20
Pmot [kW] 5.5 5.5 7.5 7.5 11 11 11 15
Q1 [m3/min] 2.50 2.94 3.74 4.32 4.98 5.74 6.76 7.73
∆t [K] 90 85 79 76 74 72 70 68
700
PK [kW] 5.00 5.55 6.56 7.29 8.14 9.11 10.50 11.70
Pmot [kW] 5.5 7.5 7.5 11 11 11 15 15
3
Q1 [m /min] --- 2.85 3.65 4.23 4.89 5.64 6.66 7.64
∆t [K] --- 100 93 89 86 83 81 79
800
PK [kW] --- 6.27 7.41 8.24 9.20 10.30 11.80 13.30
Pmot [kW] --- 7.5 11 11 11 15 15 15
Q1 [m3/min] --- --- --- 4.14 4.80 5.55 6.57 ---
∆t [K] --- --- --- 102 99 95 92 ---
900
PK [kW] --- --- --- 9.19 10.30 11.50 13.20 ---
Pmot [kW] --- --- --- 11 11 15 15 ---
3
Q1 [m /min] --- --- --- --- 4.71 5.47 --- ---
∆t [K] --- --- --- --- 112 108 --- ---
1000
PK [kW] --- --- --- --- 11.30 12.70 --- ---
Pmot [kW] --- --- --- --- 15 15 --- ---
2 --- 20
∆p nk
2510 2965 3490 3910 4355 4610 5125 5435
[mbar] [rpm]
Q1 [m3/min] 3.04 3.75 4.58 5.24 5.94 6.34 7.15 7.63
∆t [K] 32 31 30 29 29 28 28 28
300
PK [kW] 2.45 2.87 3.36 3.76 4.20 4.45 4.97 5.29
Pmot [kW] 3 4 4 5,5 5,5 5,5 7,5 7,5
Q1 [m3/min] 2.90 3.62 4.44 5.10 5.80 6.20 7.01 7.49
∆t [K] 45 43 41 40 39 39 38 38
400
PK [kW] 3.11 3.65 4.27 4.79 5.34 5.66 6.31 6.71
Pmot [kW] 4 5.5 5.5 5.5 7.5 7.5 7.5 11
3
Q1 [m /min] 2.78 3.49 4.32 4.98 5.68 6.08 6.88 7.37
∆t [K] 59 55 52 51 50 49 48 48
500
PK [kW] 3.77 4.42 5.19 5.81 6.48 6.86 7.65 8.14
Pmot [kW] 5.5 5.5 7.5 7.5 7.5 11 11 11
3
Q1 [m /min] 2.67 3.38 4.21 4.87 5.56 5.96 6.77 7.26
∆t [K] 73 68 65 63 61 60 59 58
600
PK [kW] 4.42 5.20 6.10 6.83 7.62 8.07 9.00 9.56
Pmot [kW] 5.5 7.5 7.5 7.5 11 11 11 11
Q1 [m3/min] 2.56 3.28 4.10 4.76 5.46 5.86 6.67 7.16
∆t [K] 89 82 77 75 72 71 70 69
700
PK [kW] 5.08 5.97 7.01 7.86 8.76 9.28 10.30 11.00
Pmot [kW] 7.5 7.5 11 11 11 11 15 15
3
Q1 [m /min] --- 3.18 4.01 4.67 5.37 5.77 6.58 7.06
∆t [K] --- 97 90 87 84 83 81 80
800
PK [kW] --- 6.75 7.93 8.88 9.90 10.50 11.70 12.40
Pmot [kW] --- 7.5 11 11 11 15 15 15
Q1 [m3/min] --- --- 3.92 4.58 5.28 5.68 6.49 6.97
∆t [K] --- --- 104 100 96 95 92 91
900
PK [kW] --- --- 8.84 9.90 11.00 11.70 13.00 13.80
Pmot [kW] --- --- 11 11 15 15 15 15
3
Q1 [m /min] --- --- --- 4.49 5.19 5.59 --- ---
∆t [K] --- --- --- 113 109 107 --- ---
1000
PK [kW] --- --- --- 10.90 12.20 12.90 --- ---
Pmot [kW] --- --- --- 15 15 15 --- ---
2 --- 21
2.6 Lubricating Oil

The type of lubricating oil to be used is marked on the blower block.
Ordering: see ’Spare Parts, Operating Materials, Service’ chapter 11.
2.6.1 Recommended lubricant
OMEGA OMEGA OMEGA OMEGA

FLUID---M100 FLUID---M220 FLUID---SB220 FLUID---SF220
Description Mineral oil Mineral oil Synthetic oil lubricating oil
free of mineral
oil
Oil type C, CL, CLP100 C, CL, CLP220 SB 220 SF 220
DIN 51517 DIN 51517
Ambient tem- ---15 ˚C to ---5 ˚C to 40 ˚C ---15 ˚C to ---25 ˚C to
perature 40 ˚C 40 ˚C 40 ˚C
Oil temperature ---5 ˚C to 80 ˚C 2 ˚C to 110 ˚C ---5 ˚C to ---25 ˚C to
120 ˚C above 110 ˚C
Tab. 26 Recommended lubricant
2.6.2 Lubricating oil capacity
Drive---end [l] 0.15 ± 15 %

Gear---end [l] 0.13 ± 15 %
Tab. 27 Lubricating oil capacity
2.7 Electrical connection

See electrical connections in chapter 13.3 for further information.
2.7.1 Power supply

The machine is designed for an electrical supply in accordance with EN60204---1
(IEC 204---1), section 4.3. In the absence of user---specified alternatives, the limits given in
this standard must be adhered to. It is recommended that the supplier and user confer and
agree on the basis of EN60204---1, annex B.
The machine requires a symmetrical three---phase power supply.
In a symmetrical three---phase supply the phase angles and voltages are all the same.
The machine may only be operated with a neutral point earthed TN or TT three---phase sup-
ply. An IT supply is not permitted.
2.7.2 Power supply specifications

The following conductor cross---sections (multicore Cu) and fusing (HRC fuse slow---blow)
are given according to VDE 0100, parts 430 and 523, for ambient temperatures of 30˚C and
laying method C. If other conditions prevail (higher temperature, non---standard cable laying
or cable lengths above 50 m) the cross---section should be checked and adjusted accor-
dingly.
2 --- 22
2.7.2.1 Rated power supply: 230V, 3---ph, 50Hz
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Current draw [A] ±10% 5.4 7.5 9.9 12.9 17.2 23.5 34 47
Tab. 28 Current draw 230V/3/50Hz
Type of starting: star---delta
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Max. slow---blow fusing [A] 10 10 16 20 25 35 50 63
Recommended supply cable 2x 2x 2x 2x 2x 2x
7x2.5 7x2.5
[mm2] 4x2.5 4x2.5 4x2.5 4x4 4x6 4x6
Tab. 29 Power supply data for star ---delta starting 230V/3/50Hz
Type of starting: direct online
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Recommended supply cable
4x2.5 4x4 4x4 4x6 4x6 4x10 4x16 4x25
[mm2]
Tab. 30 Power supply data for direct online starting 230V/3/50Hz
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Current draw [A] ±10% 3.1 4.3 5.7 7.4 9.9 13.5 20 27
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

7x1.5 7x1.5
[mm2] 4x1.5 4x2.5 4x2.5 4x2.5 4x2.5 4x4
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

4x1.5 4x1.5 4x2.5 4x4 4x4 4x6 4x6 4x10
[mm2]
2 --- 23
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Current draw [A] ±10% 2.5 3.4 4.6 5.9 7.9 10.8 16 22
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

7x1.5 7x1.5
[mm2] 4x1.5 4x1.5 4x2.5 4x2.5 4x2.5 4x2.5
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

4x1.5 4x1.5 4x1.5 4x2.5 4x4 4x4 4x6 4x6
[mm2]
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Current draw [A] ±10% 3.1 4.3 5.7 7.4 9.9 13.5 20 27
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

7x1.5 7x1.5
[mm2] 4x1.5 4x2.5 4x2.5 4x2.5 4x2.5 4x4
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

4x1.5 4x1.5 4x2.5 4x4 4x4 4x6 4x6 4x10
[mm2]
2 --- 24
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

Current draw [A] ±10% 2.5 3.4 4.6 5.9 7.9 10.8 16 22
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

7x1.5 7x1.5
[mm2] 4x1.5 4x1.5 4x2.5 4x2.5 4x2.5 4x2.5
Motor power [kW] 1.5 2.2 3 4 5.5 7.5 11 15

4x1.5 4x1.5 4x1.5 4x2.5 4x4 4x4 4x6 4x6
[mm2]
2 --- 25
Safety and Responsibility
3 Safety and Responsibility
Disregard of this notice can result in serious injury.
DANGER
. Read the service manual carefully and take notice of the contents for
safe machine operation.
The machine is manufactured to the latest engineering standards and acknowledged safety
regulations. Nevertheless, the dangers can arise by its operation:
D Danger to life and limb of the operator or third parties
D Detrimental to the machine and property.
. Use this machine only if it is in a technically perfect condition and only for the purpose
for which it is intended, observing all safety measures and the instructions in the service
manual.
. In particular, immediately rectify (have rectified) any faults that could be detrimental to
safety.
3.1 Correct Use

The machine is intended solely for industrial use in generating low---pressure compressed
air. Any other use is considered incorrect. The manufacturer is not liable for any damages
resulting from such unspecified use or application. The responsibility, in case, lies solely with
the user.
Correct use also includes compliance with the instructions in this manual.
3.2 Incorrect Use

Never direct compressed air at persons or animals.
Do not use untreated compressed air for breathing purposes.
Do not use untreated compressed for any application that will bring it into direct contact with
foodstuffs.
Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
Do not operate the machine in areas in which specific requirements with regard to explosion
protection are applied.
3 --- 26
3.3 User’s Responsibilities

Observe statutory and accepted regulations
Observe relevant statutory and accepted regulations during installation, operation and main-
tenance of the machine.
For example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
3.3.1 Qualified personnel

Ensure that operating, installation and mainetnance personnel are qualified and authorised
for their tasks.
These are people who, by virtue of their training, knowledge and experience as well as their
knowledge of the prevailing conditions, can assess the work to be done and recognise the
possible dangers involved.
Operating personnel
Authorised operating personnel:
D must be adult,
D must be conversant with and adhere to the safety instructions and sections of the ser-
vice manual relevent to operation of the machine,
D must have received adequate training and authorisation to operate electrical and com-
pressed air devices.
Installation and maintenance personnel

Authorised installation and maintenance personnel:
D must be adult,
D must be conversant with and adhere to the safety instructions and sections of the ser-
vice manual relevent to installation and maintenance of the machine,
D must be fully conversant with the safety concepts and regulations of electrical and com-
pressed air engineering,
D must be able to recognise the possible dangers of electrical and compressed air de-
vices and take appropriate measures to safeguard persons and property,
D must have received adequate training and authorisation for the safe installation and
maintenance on these machines.
Adhere to inspection schedules and accident prevention regulations

The machine is subject to local inspection schedules.
Prohibition of modifications
Modifications may only be carried out with the express permission of KAESER.
Do not subject pressure---bearing parts to welding, heat treatment or mechanical change.
Examples of pressure components are: pipes, blowoff valves, silencers, T---pieces, check
valves and unloaded start valves.
3 --- 27
3.4 Dangers
The general safety instructions in this chapter indicate the possible dangers and how to deal
with them.
Special safety instructions are found in this service manual at the beginning of each chapter
or directly before handling instructions.
3.4.1 Awareness of danger sources

Here are to be found the various types of danger that can arise in connection with machine
operation.
Electricity
. Allow only qualified electricians or trained personnel under the supervision of a qualified
electrician to work on electrical equipment according to electrical engineering regula-
tions.
. Before initial start---up, make sure that adequate protection against electric shock from
direct or indirect contact with the machine is installed and checked.
. Isolate all phases of the main power supply.
. Check that there is no voltage present.
. Switch off any external power sources.
These can be, for example, power supplied through a volt---free (dry) contact or electri-
cal machine heating.
. Use fuses corresponding to the machine power.
. Regularly check that all electrical connections are tight.
Pressure forces
Compressed air is a contained force. Uncontrolled release of this energy can cause serious
injury or death.
Before all work on a pressure system:
. close shut---off valves or otherwise isolate the machine from the air network to ensure
that no compressed air can flow back into the machine,
. de---pressurize all pressurized components and enclosures.
. Do not carry out welding, heat treatment or mechanical modifications to pressure com-
ponents (e.g. pipes and vessels) as this influences the component’s pressure resi-
stance.
The safety of the machine is then no longer ensured.
Compressed air quality
. Use appropriate systems for air treatment before using the compressed air from this
machine as breathing air and/or for the processing of foodstuffs.
. Never directly inhale compressed air.
. Use foodstuff---compatible lubricating oil whenever compressed air is to come into con-
tact with foodstuffs.
Spring forces
Springs under tension or compression represent contained energy. Uncontrolled release of
this energy can cause serious injury or death.
Blowoff valves and unloaded start valves (option) are under powerful spring loading.
. Do not open or dismantle valves.
3 --- 28
Rotating components
Touching the fan wheel (sound enclosure) or the belt drive while the machine is switched on
can result in serious injury.
. Check that there is no voltage present.
. Wear close---fitting clothes and a hair net if necessary.
. Make sure all covers and safety guards are in place and secured before switching on.
Temperature
. Avoid contact with hot components.
. Wear protective clothing.
. When welding is taking place on or near the machine take adequate measures to en-
sure that no parts of the machine or any oil vapours can ignite because of sparks or
heat.
Noise
. Wear hearing protection if necessary.
Operating materials
. Strictly forbid fire, open flame and smoking.
. Follow safety regulations when dealing with lubricants and chemical substances.
. Avoid contact with skin and eyes.
. Do not inhale oil mist or vapour.
. Do not eat or drink while handling lubricating fluids.
. Keep suitable fire extinguishing material on hand.
. Use only KAESER approved operating materials.
Unsuitable spare parts

. Use only spare parts approved by the manufacturer for use in this machine. Unsuitable
spare parts compromise the safety of the machine.
. Use only genuine KAESER parts for pressure components.
Conversion or modification of the machine

. Do not permit conversion or modification of the machine as this can compromise func-
tion and safe working.
3 --- 29
3.4.2 Safe machine operation

Here is found information to support safe conduct with the machine.
Transport
. Use suitable lifting gear that conforms to local safety regulations.
. Attach lifting gear only to the designated points on the machine.
. Make sure the centre of gravity is correctly positioned to avoid the machine tipping.
. Make sure the danger zone is clear.
Installation
. Make sure no power is applied when electrical connections are made.
. Only use only electrical cables that are suitable and approved for the the loads applied.
. Install or remove pressure lines only when they are in the depressurised condition.
. Only use pressure lines that are suitable and approved for the maximum working pres-
sure and medium used.
. Do not allow connecting pipes to be under mechanical stress.
. Do not step onto machine components to climb up the machine.
Location
. Install the machine in a suitable room.
If installed outdoors, the machine must be protected from frost, direct sunlight, dust and
rain.
. The machine is not explosion---proof.
Do not operate in areas in which specific requirements with regard to explosion protec-
tion are applied.
For instance, the requirements of the ATEX directive 94/9/EC ”Equipment and Protective
Systems for use in Explosive Atmospheres”.
. Ensure adequate ventilation.
. Observe the required ambient conditions:
D ambient temperature and humidity,
D clean inlet air with no damaging contaminants,
D inlet air free of explosive or chemically unstable gases or vapours,
D inlet air free of acid---forming substances, particularly ammonia, chlorine or hydro-
sulphide.
. Do not position the machine in the warm exhaust air from other machines.
. Ensure accessibility so that all work on the machine can be carried out without danger
or hindrance.
Operation
. Carry out regular inspections:
D for damage,
D of the safety devices,
D of components needing to be monitored.
. Machines drawing in air from the surroundings should not be operate without an air fil-
ter.
3 --- 30
Maintenance
. Make sure the machine is disconnected from electrical power, is voltage---free and de-
pressurised before commencing any maintenance work.
. Wear close---fitting, flame---resistant clothing. Wear protective clothing as necessary.
. Do not leave any loose components, tools or cleaning rags on the machine.
. Components removed from the machine can still be dangerous.
Do not open or destroy removed components as some.
Decommissioning / disposal
. Drain all fluids from the machine and dispose of in accordance with local environmental
regulations.
. Dispose of the machine in accordance with local environmental regulations.
3.4.3 Organising
. Designate personnel and their responsibilities.
. Give clear instructions on reporting faults and damage to the machine.
. Give instructions on fire reporting and fire---fighting measures.
3.4.4 Danger zones

The table gives information on the zones dangerous to personnel.
Only authorised personnel may enter these zones.
Activity Danger zone Authorised personnel

Transport 3 m radius from the machine. Installation or transport per-
sonnel.
All personnel excluded during

transport.
Beneath the lifted machine. All personnel excluded!
Installation Within the machine. Installation personnel
1 m radius of the machine and power
lines.
Operation 1 m radius from the machine. Operating personnel
2 m radius from the cooling air discharge.
Maintenance Within the machine. Maintenance personnel
1 m radius from the machine.
Tab. 43 Danger zones
3 --- 31
3.5 Safety Devices

Do not change, bypass or disable safety devices.
Do not remove or obliterate labels and notices.
Ensure that labels and notices are clearly legible.
More information on safety devices is contained in chapter 4 ’Design and Function’, sec-
tion 4.2 ’Safety Devices’.
3.6 Safety Signs

The table lists the various safety signs used and their meanings. The diagram shows the
positions of the signs on the machine.
Loca- Sign Meaning

tion
1 Hot surface
Danger of burns from touching hot components.
. Do not touch the surface.
. Wear long---sleeved garments (not synthetics such
as polyester) and protective gloves.
2 Hot surface / noxious gase
Burns from contact with hot components or gases.
. Do not touch the surface.
. Wear long---sleeved garments (not synthetics such
as polyester) and protective gloves.
. Noxious gases; do not inhale.
3 Dangers from spring force
. Carefully tension the V---belt.
4 Direction of motor rotation
. Check motor rotation direction to ensure correct flow
direction.
Tab. 44 Safety signs
3 --- 32
Fig. 1 Location of safety signs
3.7 In Emergency
3.7.1 Fire fighting
Suitable extinguishing agents:

D foam
D dry extinguishing agent
D carbon dioxide
D sand or earth
Unsuitable or unsafe extinguishing agents:

D intense water jet.
3.7.2 Lubricating oil
Contact with the skin:

. wash off immediately.
Contact with the eyes:

. rinse thoroughly with lukewarm water and seek medical assistance.
3.8 Environmental Protection

Do not allow lubricating oil to escape to the environment or into the sewage
system.
Store and dispose of operating materials and replaced parts in accordance with local envi-
ronment protection regulations. Observe national regulations. This applies particularly to
parts contaminated with lubricating oil.
3 --- 33
3.9 Warranty
This service manual contains no independent warranty committment.
Our general terms and conditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is in-
tended under the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with
the user to determine its suitability for his specific application.
. Obtain confirmation from the manufacturer that the machine is suitable for your specific
application.
Furthermore, we accept no warranty obligation for:
D the use of unsuitable parts or operating materials,
D unauthorised modifications,
D incorrect maintenance,
D incorrect repair.
Correct maintenance and repair includes the use of genuine Kaeser spare parts and operat-
ing materials.
3 --- 34
Design and Function
4 Design and Function
4.1 Machine Overview

The machine is equipped with a KAESER blower block featuring OMEGA Profile rotors.
4.1.1 Blower block
Fig. 2 Blower block overview
1 Primary rotor 7 Gear ---end oil drain

2 Inlet port 8 Gear ---end oil sight glass
3 Secondary rotor 9 Drive ---end oil sight glass
4 Gear ---end oil filling port 10 Drive ---end oil drain
5 Drive ---end oil filling port 11 Drive shaft
6 Discharge port
Principle of Compression
Fig. 3 Principle of Compression
A pair of rotors with intermeshing lobes rotate in opposite directions within a casing. The
rotors are synchronised by timing gears on one end. Air in the block inlet is trapped be-
tween the rotors and the casing and moved round to the discharge port.
There is no contact between the rotors themselves and the casing so no oil film lubrication is
needed. The air (or other medium) is transported through the block without being com-
pressed and pushed out against whatever resistance may be present in the discharge line.
4 --- 35
Design and Function
4.1.2 Machine
Fig. 4 Drawing air from the surroundings
A BB 53 C pr, BB 68 C pr, BB 88 C pr
B BB 52 C pr
1 Inlet silencer 7 Unloaded ---start valve (option)
2 Drive motor 8 Blowoff valve
3 Blower block 9 Discharge silencer
4 Check plate (option) 10 Maintenance indicator (machine without
5 Base frame sound enclosure)
6 Indicators (machine without sound
enclosure)
Function
The blower block (3) and drive motor (2) are mounted on a common base frame (5). Power
transmission is via V---belts.
Air is drawn into the block through an inlet silencer (1). The inlet silencer contains a filter.
Air flows vertically through the dischare silencer (9).
Air pressure is measured at the connection with the discharge silencer.
4 --- 36
Design and Function
4.1.3 Sound enclosure
Fig. 5 Sound enclosure overview
B BB 52 C pr
1 Cooling air outlet 6 Base frame
2 Rear side 7 Air discharge side
3 Indicators (option) 8 Cooling air inlet
4 Maintenance access panel 9 Air inlet
5 Side panel 2x
The sound enclosure has several functions when it is closed:

D sound damping
D protection against contact
D Airflow control
Design
BB 52 C pr:
The rear panel of the sound enclosure is fitted to machine.
This powder---coated panel is lined with sound damping material.
BB 53 C pr, BB 68 C pr, BB 88 C pr:
The load---bearing, transportable, closed base frame (6) supports the enclosure.
The powder---coated panels are lined with sound damping material.
Airflow control
A fan on the motor draws air into the enclosure through the air inlet opening (8) in the rear to
provide cooling for the motor and the rest of the machine.
An extractor fan (if provided) strengthens the air flow to improve cooling in the enclosure.
Air to be compressed is drawn in through a separate air duct. This ensures that the air to be
compressed is at ambient temperature.
4 --- 37
Design and Function
4.1.4 Blowoff valve

The blowoff valve protects the system from excessive pressure. It is factory set.
Fig. 6 Blowoff valve
B BB 52 C pr
1 Pressure line connection
NPT A B C ØD E F G H
2” 180 76 83 G11/4 231 50 25 18
2.5” 200 89 95 --- --- --- --- ---
Tab. 45 Blowoff valve dimensions
4 --- 38
Design and Function
4.1.5 Pressure indicator

The pressure indicator shows the pressure in the blower block discharge port.
Fig. 7 Location of the pressure indicator
1 Pressure indicator A Machine with sound enclosure

B Machine without sound enclosure
4.1.6 Compensator
The compensator serves:
D to make inlet and outlet connections to silencers and accessories,
D to join plain pipework to a flange connecting piece,
D as a vibration decoupler between the machine and the pipeline.
Fig. 8 Compensator
1 Connecting flange 3 Hose clamp

2 Compensator hose
4 --- 39
Design and Function
DN l1 A* D L
50 75 50 ± 10 60.3 150
65 75 50 ± 10 76.1 150
* Distance to the connecting pipe
Tab. 46 Compensator dimensions
4.2 Safety Devices

The following safety devices are provided and may not be modified:
D Blowoff valve
The blowoff valve protects the system from excessive pressure. This is factory set.
D Covers over moving parts and electrical connections protect against accidental contact.
D The sound enclosure protects against noise.
4 --- 40
Installation and Operating Conditions
5 Installation and Operating Conditions
5.1 Surroundings
. Strictly forbid fire, open flame and smoking.
. When welding is taking place on or near the machine take adequate measures to en-
sure that no parts of the machine or any oil vapours can ignite because of sparks or
heat.
. The machine is not explosion---proof.
Do not operate in areas in which specific requirements with regard to explosion protec-
tion are applied.
For instance, the requirements of the ATEX directive 94/9/EC ”Equipment and Protective
Systems for use in Explosive Atmospheres”.
. Observe the required ambient conditions:
D ambient temperature and humidity,
D clean inlet air with no damaging contaminants,
D inlet air free of explosive or chemically unstable gases or vapours,
D inlet air free of acid---forming substances, particularly ammonia, chlorine or hydro-
sulphide.
. suitable fire extinguishing material at hand.
5.2 Installation Conditions
5.2.1 Place of installation

D The floor must be level, firm and able to bear the weight of the equipment.
D No special foundation is necessary.
D The machine must be secured in position and prevented from sliding.
D If installed outdoors, the equipment must be protected from frost, direct sunlight, dust
and rain.
D Ensure accessibility so that all work on the machine can be carried out without danger
or hindrance.
D Apertures for ventilation air inlet and outlet must not be obscured in any way.
5.2.2 Ventilation
If the inlet aperture is insufficient a dangerous vacuum can be created in the

machine room.
. Ensure the machine room is adequately ventilated.

. Make sure that the machine can only operate when the inlet aperture
is actually open.
5 --- 41
Installation
6 Installation
6.1 Safety
Voltage!
DANGER There is danger of fatal injury caused by touching electrically live compo-
nents.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Check that no voltage is present.
Uncontrolled pressure release!
WARNING Serious injury or death can result from loosening or opening components
under pressure.
. De---pressurize all pressurized components and enclosures.
Blowoff valves and unloaded-- start valves (option) are under powerful
spring loading.
WARNING
Fatal injury may occur from incorrect opening of spring---loaded compo-
nents.
Installation work may only be carried out by authorised personnel!
All functioning parts are factory set.

Changes may not be made without the permission of the manufacturer.
6.2 Report any Transport Damage

. Check the machine for visible and hidden transport damage.
. Inform the carrier and the manufacturer in writing of any damage.
6.3 Safety devices installed by the user

The machine has no electronic monitoring of safety---relevant parameters such as tempera-
ture, pressure or current draw and we recommend that appropriate safety devices should
be installed by the user.
These external devices must be interlocked with the machine’s electrics to stop the ma-
chine in the event of a fault.
Minimum requirements:
Monitoring and machine shutdown in the case of exceeding
D the maximum permissible final pressure or pressure rise (∆p),
D the maximum permissible discharge temperature,
D the maximum permissible current draw (overload cut ---out).
6 --- 42
Installation
The pressure relief valve and check plates are not devices to regulate pres-
sure below the maximum permissible.
6.4 Making the Compressed Air Connection

Pre-- condition: The machine is factory assembled up to the point of connection to the
discharge silencer.
. A flexible connector must be used to connect to the users pipeline.

. Split cuffs (1) delivered with machines with sound enclosures are clamped round the
compensator hose on the port end (2) and secures with counter---sunk screws.
Fig. 9 Fitting the split cuff
1 Split cuff
2 Compensator hose
If the system is such that there is a tendency for air / gas under pressure to
flow back to the machine when it is stopped, a non---return device (check ---
plate) must be installed to allow for unloaded starting of the machine.
6.5 Electrical Connection

Have the electrical connection made only by a qualified and authorised electrician.
Carry out protection measures as stipulated in relevant regulations (IEC 364 or DIN
VDE 0100, for example) and in national accident prevention regulations (BGV A2 in Ger-
many). Also observe the regulations of the local electricity supplier.
. The user must provide the machine with a lockable mains switch.
This could be, for example, a mains power switch with fused supply. If a circuit breaker
is used it must be suitable for the motor starting characteristics.
. If the machine is driven by a frequency converter the specification given in the docu-
mentation for this unit should be taken into consideration.
. Connect the drive motor to the mains power supply in accordance with the electrical
diagram in chapter 13.3.1.
. Connect the sound enclosure extractor in accordance with local regulations and the
instructions given in chapter 13.3.2.
. The user’s safety devices must be correctly connected to the machine’s electrical sy-
stem by a qualified person.
6.6 Anchoring the Machine

The machine, with or without sound enclosure, may be anchored to the floor. Details of the
fixing holes are contained in the dimensional drawing in chapter 13.2.
. Use appropriate bolts to anchor the machine.
6 --- 43
Initial Start--- up
7 Initial Start ---up
7.1 Safety
Voltage!
DANGER
There is danger of fatal injury caused by touching electrically live compo-
nents.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked off).
Uncontrolled pressure release!
WARNING
Serious injury or death can result from loosening or opening components
under pressure.
Initial start---up may only be carried out by authorised personnel!
Before switching on ensure that:
D no one is working on the machine,

D all panels are in place and secured.
7.2 To be Observed Before Every Initial Start---up

A trained specialist may only carry out the initial start---up procedure.
Incorrect or improper start---up can cause damage to the machine.
Special measures on re---starting after storage:
Storage period longer Action to take

than...
12 months . Change the oil.
. Have the motor bearings checked by an authorised
KAESER service agent.
36 months . Have the overall technical condition checked by an autho-
rised KAESER Service agent.
7 --- 44
Initial Start--- up
7.3 Check Installation and Operating Conditions

Cover all points in the checklist before starting the machine.
Check Chapter Done?

1 . Are the operators full conversant with safety regulations?
2 . Are all conditions for installation in order? 5.2
3 . Has automatic machine shutdown by the user’s safety de- 6.3
vices in the event of a fault been achieved?
4 . Have the rotation direction of the drive and extractor mo-
tors been checked?
5 . Supply cable section and fuse rating adequate? 2.7.2
6 . All electrical connections checked for tightness?
7 . Is there adequate lubricating oil in the drive---end and
gear---end of the block?
(check oil sight glasses)
8 . Has the drive shaft been turned by hand to check that it
turns freely?
9 . V---belt tension checked? 10.3.1
10 . Have the check---plate, valve and regulator been correctly
fitted?
11 . Is the connection to the pipeline made with a flexible joint?
12 . Has the silicone seal protecting the outdoor installed ma-
chine been checked for leaks?
Tab. 47 Installation conditions checklist
7.4 Checking Direction of Rotation

The blower block rotors must rotate in the correct direction. The drive shaft must rotate
anti---clockwise. Arrows indicating direction of rotation are to be found on the block and belt
guard.
An arrow is also to be found on the extractor to indicate its correct direction of rotation.
When turning in the correct direction the extractor blows air strongly out of the enclosure.
When turning in the wrong direction the extractor will still blow air out of the enclosure but
only weakly.
Rotating parts can cause severe injury.
WARNING
Serious injury is possible.
. Do not remove panels.
Incorrect direction of rotation!
CAUTION
If the block rotors turn in the wrong direction the direction of airflow through
the machine will also be wrong. Drawing in foreign bodies or creating a high
vacuum can lead to damage or even destruction of the block.
. Checking the direction of rotation.
. Remove the inlet silencer filter maintenance cover or the inlet filter and/or the inlet
check---plate if fitted.
7 --- 45
Initial Start--- up
. Check the supply with a phase sequence indicator.

. If the drive motor turns in the wrong direction, change the motor supply phases L1 and
L2.
. If the extractor motor turns in the wrong direction, change the motor supply phases L1
and L2.
Alternatively, the direction of rotation can be checked by briefly switching the

machine on and off again.
. Check rotation direction with pipework disconnected.

. Switch the machine off as soon as the direction of rotation is seen and
compare it with the direction arrow on the belt guard.
7 --- 46
Operation
8 Operation
8.1 Switching On and Off

Switching on and off follow to a large extent the procedure established for the equipment
provided for this.
D Maximum switchings per hour --- 6.
D Start the machine only from the standstill state.
D Measures must be taken for unloaded starting if there is back pressure in the discharge
line.
8.1.1 Switching on
Compressed air!
WARNING
Serious injury is possible.
. Never direct compressed air at persons or animals.
. Ensure that:
D no one is working on the machine,
D all panels are in place.
. Switch on at the user’s control cabinet.
8.1.2 Switching off

. Switch off at the user’s control cabinet.
8.2 On, Off and Speed---change Switching of a Two---speed Motor
8.2.1 Operating in low speed
Switching on:
. Select low speed and switch on the motor.
Type of starting: direct online or star---delta.
Switching off:
8 --- 47
Operation
8.2.2 Operating in two speeds
Switching on:
. Select low speed and switch on the motor.
Type of starting: direct online or star---delta.
Switching over from low to high speed:

. When the motor has reached its lower speed, switch over to higher speed.
Switching over from high to low speed:

. Switch the motor off and when it comes to a stop switch on in the lower speed.
Switching off:
8.3 Fan function

It is essential that the sound enclosure fan functions correctly.
The machine can be damaged by elevated temperature in the sound

enclosure!
CAUTION
Overheating can lead to breakdown in the blower and other components.
. If the fan stops during operation a sufficient flow of air must be provided
or the machine must be stopped immediately.
8 --- 48
Event Recognition and Fault Rectification
9 Fault Finding and Removal
Inform KAESER Service if the fault cannot be removed by the measures suggested.
Do not attempt fault removal measures other than those given in this manual.
9.1 Abnormal noise when running

Possible cause Remedy
Too much backlash in the timing gears. Contact KAESER service.
Bearing play to large. Contact KAESER service.
Rotors rub against each other. Compare the operating conditions, with
regard to pressure differential and speed,
with the machine technical specification.
Check for dirt in the block and clean if
necessary.
Tab. 48 Abnormal noises and remedies
9.2 Block too hot

Pressure differential too great. Check and correct pressure differential.
Clogged inlet filter reducing air intake vol- Clean the inlet filter.
ume.
Rotor clearance too large. Contact KAESER service.
Tab. 49 Block becomes too hot --- remedy
9.3 Lubricating oil leakage

Oil level too high. Oil leaks from the gas Drain oil until the level is in the centre of the
drain. sight glass.
Oil leaking from around the drive shaft. Replace the shaft sealing ring.
Tab. 50 Oil leakage and remedies
9.4 Reduced air inlet flow

Rotor clearance to large because of wear. Contact KAESER service.
Probably because of contaminated intake
air/gas.
Intake resistance too high. Clean the inlet filter.
Tab. 51 Reduced inlet flow and remedies
9 --- 49
Event Recognition and Fault Rectification
9.5 Black film on the oil sight glasses

Oil not changed at the correct interval. Change the oil. Clean or renew the sight
glass.
Insufficient oil. Change the oil. Clean or renew the sight
glass.
Oil overheated. Contact KAESER service.
Blower block overloaded. Contact KAESER service.
Tab. 52 Black film on the oil sight glasses and remedies
9.6 Water in the oil

Condensate build---up by prolonged sto- Change the oil.
rage and high humidity.
Tab. 53 Water in the oil and remedies
9.7 Sound enclosure overheating (if fitted)

Extractor motor defective or turning in the Contact KAESER service.
wrong direction.
Cooling air inlet and/or outlet obstructed. Check that cooling air inlet and outlet are
free.
Check the temperature of the cooling air
intake.
Drive motor overloaded. Check operating conditions.
Tab. 54 Sound enclosure overheating and remedies
9.8 Other Faults

Drive motor defective. Bearing damage or Contact KAESER service.
windings short.
Blower block defective. Contact KAESER service.
Tab. 55 Other faults and remedies
9 --- 50
Maintenance
10 Maintenance
The sound enclosure access panel must be removed to carry out maintenance on the ma-
chine.
A key is provided for unlocking the enclosure panels.
10.1 Safety
Disregarding these notes and/or improper handling may result in serious injury.
Electric shock can kill!
DANGER
Contact with live electric components can cause serious injury or death.
. Ensure that the power supply cannot be switched on again (lock out).
There is considerable danger of injury or death if spring ---loaded com-

ponents are incorrectly opened.
WARNING
Blowoff valves and unloaded---start valves (option) are under powerful
spring loading.
Compressed air can cause serious injury!
WARNING
Serious injury or death can result from loosening or opening components
under pressure.
. Close shut---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the machine.
Machine damage caused by leakage
CAUTION
Leaks result in loss of oil and reduced performance.
Damage or complete breakdown can result.
. Carry out a trial run after maintenance and service work.
. Carry out a visual check of the machine.
Maintenance work may only be carried out by authorised personnel!
Before switching on again ensure that:
D no maintenance personnel are working on the machine,

D all panels are in place and secured.
10 --- 51
Maintenance
10.2 Maintenance Schedule
Maintenance intervals are recommendations only and should be adjusted to

suit the installation and operating conditions.
. Keep a log of all service work.

This enables the frequency of individual maintenance tasks and deviations from Kaeser’s
recommendations to be determined. A prepared list is provided in chapter 10.9.
10.2.1 Regular maintenance work
When operating conditions are unfavourable (e.g. dusty atmosphere) or

when the equipment is in frequent use, maintenance tasks must be carried
out more frequently.
Interval Maintenance tasks see chapter

24 h after initial Check the V---belt tension. 10.3.1
start---up
50 h after initial Check all electrical terminals and tighten if necessa-
start---up ry.
500 h after initial Change the oil. 10.5
start---up
500 h or monthly Check the oil level. 10.4.1
Check the V---belt tension. 10.3.1
Check the air intake filter maintenance indicator. 10.6
According to the mo- Re---greasing interval, grease type and quantity for
tor nameplate re---greasable bearings *
3000 h or annually Change the oil.* 10.5
Annually Check all electrical terminals and tighten if necessa-
ry.
Check the V---belt tension. 10.3.1
Check the air filter and change if heavily contamina- 10.6.2
ted.
Checking the blowoff valve. 10.7
12000 h or after Change the V---belts. 10.3.2
2 years
12000 h or after Recommended replacement of non---greasable
3 years motor bearings.
36000 h Recommended bearing change on motors with
greasing intervals.
After 2 years Check the silicone seal on the outside of the sound
enclosure for leaks and repair or replace as neces-
sary.
h = operating hours
* The replacement and re---greasing interval my be varied. Bearings should be re---grea-
sed more often when ambient temperatures are high.
Tab. 56 Regular maintenance work
Since they are more effected by temperature, the changing intervals of foodstuff---compati-
ble oils should be checked individually with KAESER.
10 --- 52
Maintenance
10.3 Tensioning and Changing the V---belts

Pre---condition: Machine switched off.
Mains power switch off and locked out.
Machine is cooled down.
10.3.1 Check the V---belt tension

The automatic belt tensioner is spring loaded and keeps the correct tension over a limited
range.
If the V---belts have stretched to the point where the marker pin (1) reaches the upper end of
the elongated hole, the V---belt tension must be manually adjusted.
Fig. 10 Belt tensioner
1 Marking pin
2 Hexagonal nut
3 Hexagonal nut
Re---tensioning the V---belts

. Loosen the hexagonal nut (2)
. Tension the V---belts with the hexagonal nut (3) until the marker pin (1) has reached the
lower end of the elongated hole again.
. Tighten the hexagonal nut (2) again.
10.3.2 Changing the V---belts

. Remove the belt guard.
. Turn the hexagonal nut (3) on the tensioner downwards.
. Turn the hexagonal adjusting nut (2) downwards until the V---belts are loose.
. Remove the V---belts.
. Lay the new V---belts loosely over the motor and block pulleys.
. Adjust the V---belt tension
. Replace the belt guard.
. Re---tension the belts after 2 hours running and again after 24 hours as the most stretch-
ing occurs over this period.
10 --- 53
Maintenance
10.4 Checking and Topping up the Oil
10.4.1 Checking the oil level

Allow the oil level to settle down.
Danger of burning from hot surfaces!
CAUTION
Skin burns are possible.
. Wear long---sleeved clothing and protective gloves.
. Work carefully.
The true oil level can be seen in the oil sight glass only when the machine is stopped.
Fig. 11 Oil level
The gear---end and drive---end oil chambers are not connected.

. Check the oil level in the sight glasses on both ends of the block.
Top up when the level drops to 3 mm below the glass centre.
10 --- 54
Maintenance
10.4.2 Top up with oil.
Material: Lubricating oil

Allow the oil level to settle down.
Lubricating oil can be an explosive!
WARNING
Danger of explosion from ignition of oil mist and vapours.
. Fire, naked flame and smoking are forbidden!
Unsuitable oil can damage the machine!
CAUTION
. Never mix different types of oil.
. Top up only with the same type of oil as already in the machine (see
label on the block).
Fig. 12 Topping up with oil
1 Plug (gear ---end) 3 Oil sight glass (gear ---end)

2 Plug (drive ---end) 4 Oil sight glass (drive ---end)
The oil level must not be above the sight glass centre or it may enter the flow chamber.
. Slowly unscrew the plugs at the gear---end and drive---end (1) and (2).
. Top up with oil.
. Screw in the plugs.
. Carry out a visual check for leaks.
10 --- 55
Maintenance
10.5 Changing the oil

Material: Lubricating oil
Oil catchment container
Danger of burns from hot components and oil.
CAUTION
. Wear long---sleeved clothing and gloves.
. Work carefully.
Dispose of the old oil in accordance with local environmental protection re-
gulations.
Drain the oil thoroughly from:

D the block gear---end
D the block drive---end
Drain the oil:
Fig. 13 Drain the oil
A BB 53 C pr, BB 68 C pr, BB 88 C pr 1 Cap

B BB 52 C pr 2 Cap
C Drive ---end 3 Oil drain tap
D Gear ---end 4 Oil drain tap
. Have an oil catchment container ready.

. Unscrew the plugs in the block ( 1 and 2; Fig. 12)
. Unscrew the caps (1 and 2) and open the oil drain taps ( 3 and 4).
. Drain the oil.
Fill with fresh oil:
. Fill with fresh oil.
. Allow the oil drain taps to remain open until oil begins to run out (bleeding the oil drain
lines).
. Check the oil level in both sight glases (Fig. 12) and top up as necessary.
. Close the oil drain taps ( 3 and 4) and screw on the caps (1 and 2).
. Screw the plugs into the block ( 1 and 2; Fig. 12)
. Carry out a visual check for leaks.
10 --- 56
Maintenance
10.6 Air Filter Maintenance
Material: Replacement part

Machine is cooled down.
10.6.1 Maintenance indicator

The maintenance indicator shows when the filter needs maintenance. When the filter el-
ement becomes clogged and flow resistance rises to a set point the maintenance signal is
given.
Machine with sound enclosure
Fig. 14 Air filter maintenance indicator
1 Indicator needle
2 Reset button
. Change the filter when the indicator needle (1) enters the red zone.
. Press the reset button (2) after filter changing to reset the indicator needle.
Machine without sound enclosure

The maintenance indicator is on the inlet silencer.
Fig. 15 Air filter maintenance indicator (option)
1 Signal ring
2 Reset button
. Change the air filter when the signal ring (1) shows red.
. Press the reset button (2) after filter changing to reset the signal ring.
10 --- 57
Maintenance
10.6.2 Change the air filter
Fig. 16 Change the air filter
A BB 53 C pr, BB 68 C pr, BB 88 C pr 1 Cover

B BB 52 C pr 2 Inlet silencer
3 Air filter
BB 53 C pr, BB 68 C pr, BB 88 C pr:

. Remove the cover (1) from the inlet silencer (2).
. Loosen the Velcro band holding the filter (3) and remove the filter.
. Place the new filter in the inlet silencer and secure with the Velcro band.
. Replace the cover.
BB 52 C pr:
. Remove the cover (1) from the inlet silencer (2).
. Remove air filter.
. Replacing the air filter.
. Replace the cover.
10.7 Checking the blowoff valve

The blowoff valve should be tested for correct function at least once a year.
Functional test with applied pressure.
WARNING
There is risk of injury from hot escaping medium.
High noise level.
. Wear ear and eye protection.
10 --- 58
Maintenance
10.8 Motor maintenance
10.8.1 Drive motor with re---greasing facility
Material: Bearing grease
Pre---condition: Motor running.
Hot components --- danger of burns
CAUTION
. Wear long---sleeved clothing and gloves.
. Work carefully.
Motors with the re---greasing facility carry information on greasing interval and grease quan-
tity on their nameplate or a special label.
Information concerning re---greasing can also be found in the motor manufacturer’s service
manual.
10.8.2 Drive motor without re---greasing facility

The drive motor bearings are permanently greased and need no re---greasing.
10.8.3 Sound enclosure extractor motor

The extractor motor bearings are permanently greased and need no re---greasing.
10 --- 59
Maintenance
10.9 Logging Maintenance Work

Machine number:
Date Maintenance task carried out Operating hours Signature
Tab. 57 Logged maintenance tasks
10 --- 60
Spares, Operating Materials, Service
11 Spares, Operating Materials, Service
11.1 Note the nameplate

Please quote the data on the nameplate for all enquiries and spare parts orders.
11.2 Ordering Consumable Parts and Operating Materials
Personal injury or machine damage may result from the use of unsuit-
able spare parts or operating materials.
CAUTION
Unsuitable or poor quality consumable parts and operating materials may
damage the machine or impair its proper function.
Damage to the machine can also result in personal injury.
. Use only genuine spare parts and authorised operating materials.
. Have an authorised KAESER service agent carry out regular mainten-

ance.
KAESER consumable parts and operating materials correspond to the original. These are
correct for use in our machines.
Machine
Name Quantity Number

Shaft seal 1 4052
Air filter 1 1250
Air filter seal 1 1251
Sealing ring / Cover seal 1 1252
Drive belts (set) 1 1800
Tab. 58 Consumable parts, machine
Lubricating oils
Name Quantity [l] Part (material)

number
1 885891.00010
KAESER OMEGA FLUID---M 100
5 885891.0
1 883816.00010
KAESER OMEGA FLUID---M 220
5 883816.0
1 831057.00010
KAESER OMEGA FLUID---SB 220
5 831057.0
1 892702.00020
KAESER OMEGA FLUID---SF 220
5 892702.00010
Tab. 59 Lubricating oil overview
11 --- 61
11.3 Maintenance Agreement

. Concluding a KAESER AIR SERVICE maintenance agreement.
Benefits to you:
lower costs and assured availability of compressed air.
KAESER AIR SERVICE offers you:
D authorised service technicians with KAESER factory training,
D increased operational security by preventive maintenance,
D energy savings by elimination of pressure losses,
D optimum conditions for operation of the air supply system,
D the security of genuine KAESER spare parts.
D increased legal security as all regulations are observed,
11.4 Service Addresses

Addresses of KAESER agents are given at the end of this manual.
11.5 Spare Parts for Service and Repair

Any inspection, maintenance or repair tasks not described in this manual
should be carried out only by an authorised KAESER service agent.
With the help of this parts list you can obtain in advance the spares you need in accordance
with your operating conditions.
11 --- 62
11.6 Declaration of Contamination

A Declaration of Contamination must be filled out and signed whenever maintenance or re-
pair work is carried out on the machine.
Pre---condition: Prepare the machine correctly for dispatch.
. drain all operating fluids

. remove filter elements
. make all openings airtight
. pack correctly
. fix a copy of the Declaration of Contamination to the outside of the packaging.
A template for this declaration is to be found on the next page.
11 --- 67
11 --- 68
De--- commissioning, Storage and Transport
12 De ---commissioning, Storage and Transport
12.1 De---commissioning
De---commissioning is necessary when:
D the machine will not be needed for some time,
D the machine is to be moved to another location,
D the machine is no longer needed,
D the machine is to be scrapped.
Temporarily De---commissioning
Pre---condition: The machine must be dry inside and out.

There must be no condensation in the machine.
. Run the machine at operating temperature for at least 30 minutes each week.
12.2 Packing
Material: Plastic sheeting
Wooden transport crate
Pre---condition: Machine is de---commissioned.

Machine is dry and cool.
. Wrap the machine in plastic sheeting.
Transport packing
A crate is required for overland transport to protect the machine from mechanical damage.
Consult an authorised KAESER service agent for advice on packing for sea or air transport.
12.3 Storage
Material: Preservative
Pre---condition: The machine must be dry inside and out.

There must be no condensation in the machine.
The machine must be adequately packed.
. Store the machine in a dry, frost---free room.

. Spray preservative onto/into the flange connections, the drive shaft and the block flow
chamber.
. Seal off the air inlet and discharge ports to prevent entry of dirt.
. Prevent entry of moisture and condensation.
. Change the lubricating oil each year.
. Turn the motor shaft by had each month about one---third of a turn.
12 --- 69
Preservative recommendations
Flange connections, drive shaft Flow chamber

ESSO RUST BAN 324 AVIA Avilub MK 2000
MOBIL OIL TECREX 39 ESSO LUB MZ 20 W/20
SHELL V---Product 9703 MOBIL Mobilarma 523 or 524
SHELL Ensis engine oil 20
or equivalent products
Tab. 60 Preserving oil
Return to service after long period of storage

. Remove the preservative from the flow chamber with cleaning solvent.
. Observe the procedures for assembly and initial start---up.
. Change the oil.
. Re---grease the bearings if they are not of the permanently greased type.
12.4 Transporting
Use only a fork truck or lifting cradle with adjustable transverse beam.
Make sure the lifting tackle capacity is sufficient for the weight of the machine.
Fork truck
Pre---condition: The whole machine must be over the forks.
Fig. 17 Transport by fork truck
Lifting cradle
Pre---condition: No pressure should bear on the sides of the machine cabinet.
12 --- 70
Fig. 18 Transport by lifting cradle
12.5 Disposal
Pre---condition: The machine is decommissioned.
When disposing of a machine, drain out all liquids and remove dirty filters.
Parts contaminated with oil must be disposed of in accordance with local

environment protection regulations.
. Completely drain the oil from the machine.

. Remove dirty filters.
. Hand the machine over to an authorised disposal expert.
12 --- 71
Annex
13 Annex
13.1 Design Data (diagram)

Data is taken from the diagram for special applications.
The design data refer to the blower block.
13 --- 72
Annex
13.1.1 Diagram OMEGA 21 PLUS
13 --- 73
Annex
13 --- 74
Annex
13 --- 75
Annex
13.2 Diagrams and Drawings
13.2.1 Dimensional drawing
13 --- 76
Annex
13.2.2 Dimensional drawing of machine without the optional sound enclosure
13 --- 81
Annex
13.3 Electrical Connection Diagram
13.3.1 Drive motor
Single---speed motor connection --- 6 pole terminal box

Type 1:
230 V / 400 V (50 Hz) = 230 V: Y/∆---start or 400 V direct in Y---connection
460 V (60 Hz) = 460 V: direct in Y---connection
Type 2:
400 V / 690 V (50 Hz) = 400 V: Y/∆---starting or 400 V direct in ∆---connection
460 V (60 Hz) = 460 V: direct in ∆---connection
Type 3:
500 V (50 Hz) / 575 V (60 Hz) ---Y = direct in Y---connection
Type 4:
500 V (50 Hz) / 575 V (60 Hz) ---∆ = direct in ∆---connection
Star---delta starting:
Star---delta is the simplest way of reducing starting current and torque. Motors can be star/
delta started whenever the supply voltage corresponds to the rated voltage of the motor in
delta connection.
The integrated PTC sensor is connected to terminals T1 and T2 in the motor terminal box
(do not apply a voltage greater than 2.5 V).
Star connection:
A star connection is obtained by joining terminals W2, U2 and V2 and feeding power to ter-
minals U1, V1 and W1.
Phase current and voltages are:
Iph = In
Uph = Un / √3
Where In is the line current and Un the line voltage.
Fig. 19 Star connection for a 3 ---phase motor
1 Star point
13 --- 86
Annex
Delta connection:
In delta connection, the end of one phase connects to the beginning of the next.
The phase current Iph and the phase voltage Uph are:
Iph = In / √3
Uph = Un
Fig. 20 Delta connection for a 3 ---phase motor
13.3.2 Sound enclosure extractor
Three---phase motor connection

Type 1: ∆---230 V / Υ---400 V (50 Hz)
Type 2: ∆---230 V / Υ---400 V (60 Hz)
Type 3: ∆---266 V / Υ---460 V (60 Hz)
Type 4: ∆---290 V / Υ---500 V (50 Hz)
Type 5: ∆---333 V / Υ---575 V (60 Hz)
Fig. 21 Extractor motor star ---delta connection
13 --- 87
Annex
Single---phase motor connection

Type 1: 115 V (60 Hz)
Type 2: 230 V (50 Hz)
Type 3: 230 V (60 Hz)
Fig. 22 Extractor motor single ---phase connection
Notes on connections
The extractor motor has a terminal box for direct supply connection.
. Connect the extractor so that it runs at the same time as the drive motor.
. Direction of airflow is out of the sound enclosure.
. Connect the ground conductor.
. Connect cables to the terminal box without mechanical stress. Allow sufficient cable
length so that the extractor motor can be removed and laid on the enclosure.
. If the fan is arranged to continue running for about 15 minutes after the blower motor
has stopped, this improves the thermal conditions in the sound enclosure.
13 --- 88
Annex
13.4 Options
13.4.1 Check plate

Necessary to prevent reversal of the normal flow direction.
Fig. 23 Check plate
1 Casing 3 Closing mechanism

2 Flange connection PN 10 4 Gasket thickness 2 mm, both sides
A B C D
DN 50 Ø 105 Ø 45 80
DN 65 Ø 124 Ø 55 100
Tab. 61 Check plate dimensions
The check plate may only be installed for horizontal flow (see arrow).
The closing mechanism fixing must be above. The top side of the valve is marked ”TOP”.
. Tighten screws diagonally to max. torque of 70 Nm.
13 --- 89
Annex
13.4.2 Unloaded start valve

The unloaded start valve allows the machine to start without load.
Model AFE 15 AFEM 15

Permissible pressure [bar] (a) Pmax up to 2 Pmax up to 2
Maximum delivery [m3/min] 15 15
Working temperature [˚C] ---15 to +160
Medium Suitable for air and all non---aggressive gases
Solenoid valve
Construction 2/2 way

Connection Inlet and outlet G 1/4
Switching function Open when de---energised
Power 10 VA
Voltage 230 V, 1---ph, 50 Hz
Plug To DIN 43650, form A, IP 65 (valve delivered without
plug)
Tab. 62 Unloaded start valve technical specification
Fig. 24 Unloaded start valve
A AFE 15 1 Solenoid valve (B)

B AFEM 15 (only for machines without 2 Adapter (A, B)
sound enclosure)
Model Ø DN Ø DN 1 Ø DN 2 ØD1 ØD2 H H1 H2 H3 H4 H5

AFE 15 G2A R4 G2 178 --- --- 165 127 47 20 74
AFEM 15 G2A R4 G2 178 G1/4 193 165 127 47 20 74
Tab. 63 Unloaded start valve dimensions
13 --- 90
Annex
Function
* only for AFEM

Fig. 25 Unloaded start valve diagram
1 Pipeline 4 Diaphragm chamber

2 Adjusting screw 5 Valve cone
3 Nozzle 6 Solenoid valve
When the machine is shut down the valve cone (5) is open.
When the machine is started, air passes through the blow---off aperture to atmosphere.
Screwing in the adjusting screw (2) reduces the gap between the valve cone (5) and its seat-
ing so that it closes at a lower flow rate. (100 mbar pressure is needed in the pipeline to
close the valve cone (5).)
Back pressure acts through the jet (3) on the diaphragm chamber (4) to close the valve
cone. The closing time is influenced by the adjusting screw (2) changing the position of the
valve cone.
Optional with AFEM:
Opening and closing the valve cone (5) during operation can be controlled by the solenoid
valve (6).
Adjusting the closing time

The valve is delivered with the closing time set at maximum.
. Loosen the nut locking the adjusting screw (2) and turn the screw.
D Clockwise: shorter closing time
D Anticlockwise: longer closing time
. Tighten the locking nut to secure the adjusting screw when adjustment is complete.
Installation
The unloaded start valve AFEM must not be installed inside the sound enclosure. Frequent
operation of the valve can cause excessive temperature rise in the enclosure.
13 --- 91
Annex
13.4.3 Starting and regulating valve

The starting and regulating valve is air/gas driven and serves for unloaded starting with an
additional regulating function.
The valve is fitted only on machines without sound enclosure.
Model: AFR 10
Permissible pressure [bar] (a) Pmax up to 2

Maximum delivery [m3/min] 10
Maximum pressure differential [mbar] 950
Regulating range [mbar] 200 to 950
Nominal size G2A
Control line connection R 1/8 A thread ISO 228
Medium Suitable for air and all non---aggressive
gases
Tab. 64 Starting and regulating valve technical specifications
Fig. 26 Starting and regulating valve
Ø DN Ø D1 L H H1 H2 H3
G2A 177 145 165 127 47 20
Tab. 65 Starting and regulating valve dimensions
13 --- 92
Annex
Function
Fig. 27 Starting and regulating valve diagram
1 Adjusting screw 5 Valve cone

2 Control air regulator 6 Diaphragm chamber
3 Valve cone 7 Nozzle
4 Pipeline 8 Adjusting screw
Unloaded starting
When the machine is stopped the valve cone (5) is open and valve cone (3) closed. When
the machine is started, air flows over the valve cone (5) and is blown off to atmosphere. The
pressure build---up in the pipeline (4) drives air/gas through the hollow spindle and nozzle
(7) into the upper diaphragm chamber (6). The resulting pressure on the diaphragm closes
the valve cone (5).
Adjusting the closing time
The closing time is adjusted by means of the adjusting screw (8) that influences the flow rate
through the nozzle (7).
D Clockwise: shorter closing time
D Anticlockwise: longer closing time
The unloaded start function only works if the pressure in the pipeline reaches about 100
mbar.
Overflow regulation
After starting, the system pressure and the pressure on the control air regulator (2) rises. As
soon as the system pressure reaches that set by the adjusting screw (1) the valve cone (3)
opens. The pressure in the upper diaphragm chamber (6) is vented to atmosphere and the
valve cone (5) opens.
The set system pressure is kept constant.
A 300 mm hose line is provided, with R1/8 threaded fitting, to connect the regulator to the
main pipeline.
Pressure setting
The control air regulator is set to atmospheric pressure when delivered.
. Lift the rubber cap from the control air regulator (2) and loosen the nut locking the ad-
justing screw (1).
. Use a screwdriver to turn the adjusting screw (1).
D Clockwise: lower pressure
D Anticlockwise: higher pressure
. Lock the screw in position after adjusting and replace the rubber cap.
13 --- 93
Annex
Maintenance
The starting and regulating valve needs no special maintenance. The blow---off aperture and
nozzle must be kept open and not clogged by dirt or paint.
Installation
The solenoid start valve can be mounted in any position except with the diaphragm housing
underneath.
The installation may not be such as to subject the valve casing to stress.
13.4.4 Solenoid starting valve

The solenoid valve opens the discharge line from the machine to atmosphere for unloaded
starting.
Model: AFM 4
Construction 2/2 way through valve

Connection G 1 1/4
Switching function Closed when de---energised
Power supply 230 V / 1---ph / 50---60 Hz
Connecting socket Type 2508 to DIN 43650 A
Seal material EPDM
Medium Suitable for air and all non---aggressive ga-
ses
Tab. 66 Solenoid starting valve AFM 4 technical specification
Fig. 28 Solenoid starting valve AFM 4
ØD A B C E F G H
G11/4 126 85 126.5 20 32 45 29
Tab. 67 Solenoid starting valve AFM 4 dimensions
Function
The valve is closed when de---energized. In this condition, pressure builds up above the dia-
phragm, pressing it down and holding the valve closed. When the valve is energized, the
chamber above the diaphragm is vented, allowing pressure of the conveying medium to lift
the diaphragm and open the valve.
13 --- 94
Annex
Model: AFM 5
Permissible pressure [bar] (a) Pmax up to 2

Maximum delivery [m3/min] 5
Nominal size R 2 1/2
Medium Suitable for air and all non---aggressive ga-
ses
Solenoid valve
Construction 2/2 way through valve

Connection G2
Switching function Closed when de---energised
Power supply 230 V / 1---ph / 50 Hz
Connecting socket Type 2508 to DIN 43650 A
Seal material EPDM
Tab. 68 Solenoid starting valve AFM 5 technical specification
Fig. 29 Solenoid starting valve AFM 5
1 Solenoid valve
2 Drive
Ø DN Ø DN1 L L1 L2 H H1 H2 H3
R2 R 2 1/2 132 132 364 188 78 141 156
Tab. 69 Solenoid starting valve AFM 5 dimensions
Function
The solenoid starting valve is closed when de---energised.
The valve is closed when the machine is switched off. When the machine is switched on and
the motor is in the star phase the valve is energised and opens. Air discharged from the
block is blown out to atmosphere.
When the motor switches to delta the valve is de---energised and closes.
Installation
The solenoid start valve can be mounted in any position except with the drive (2) under-
neath.
Maintenance
The solenoid start valve needs no special maintenance. The blow---off aperture must be kept
open and not clogged by dirt or paint.
13 --- 95
Annex
The function of the valve should be checked at regular intervals.
13.4.5 Temperature gauge switch

The temperature gauge switch indicates the temperature in the discharge port and provides
a floating relay contact by which a signal can be sent when a set temperature is reached
thereby monitoring the block discharge temperature.
Fig. 30 Bearing temperature gauge
A Machine with sound enclosure 1 Temperature gauge

B Machine without sound enclosure
Scale range [˚C] 0 to 200

Enclosure protection IP 53 front, IP 54 rear
Display Linear, class 2 to DIN 16203
Measuring system Fluid---filled
Temperature limits [˚C] ---20 to +70 for transport and storage
Electrical contact Switching capacity AC 250 V, 5 (1.5) A, single---pole micro-
switch with changeover contact
Switching differential < 3 of the scale range
[%]
Switching point ± 5 of the scale range related to the switch-
accuracy [%] ing point at rising temperature
Connection Tab connector A 6.3 x 0.8 to DIN 46244
Switching reliabilityMinimum voltage: AC 24 V,
Minimum current: 20 mA
Tab. 70 Temperature gauge switch technical specification
13 --- 96
Annex
Fig. 31 Temperature gauge connection diagram
Fig. 32 Temperature gauge switch dimensions
1 Fixing clamp width
Setting instructions
The switching point is set by a screw beneath the front plate protective cover.
Factory setting: 145 ˚C
Possible adjustment of working conditions on site:

Block discharge temperature less than 145 ˚C
If the average block discharge temperature is significantly lower than 145 ˚C the gauge
switching point can be adjusted down.
The recommended switching point is the block discharge temperature + 15 K
Block discharge temperature higher than 145 ˚C
If the average block discharge temperature is significantly higher than 145 ˚C the gauge
switching point can be adjusted upward.
Maximum permissible setting: 155 ˚C
13 --- 97
Annex
13.4.6 Thermostat
The thermostat is a temperature sensor inside the sound enclosure with a volt---free contact
set to close at 60 ˚C.
Working temperature range [˚C] 0 to 70

Type of contact Single---pole spring switch with changeover
contact.
Switching point accuracy ± 0.75K at +20˚C
Switching differential 2K1K
Maximum switching current Terminal 2: AC 16 (3) A, max. 230 V,
cos ϕ=1 (0.6)
Terminal 4: AC 8 (1.5) A, max. 230 V,
cos ϕ=1 (0.6)
Enclosure protection EN 60529, IP 54
Mounting position any
Electrical connection to the screw terminals beneath the housing
cover using conductors of up to 2.5 mm2
cross---section
Tab. 71 Thermostat technical specification
Fig. 33 Thermostat electrical diagram
13 --- 98
Annex
Fig. 34 Thermostat dimensions
13.4.7 Pressure switch

The pressure switch sends a signal when the set pressure is exceeded.
Setting range [bar] 0.08 to 2

Contacts max. 1 A / 250 V
Tab. 72 Pressure switch technical specification
Fig. 35 Pressure switch connections
1 Supply
2 Break contact
3 Make contact
13 --- 99
Annex
Fig. 36 Pressure switch
1 Switching point adjusting screw

2 Switching differential adjusting screw
3 Varnished screw
. Remove the switch protection cap

. Make the connections to the switch terminals.
. Set the switching point (1) with the machine in operation.
. Set the switching differential (2).
. Varnish the adjusting screws (1 and 2) to fix their settings.
Do not adjust the varnished screw (3).
13.4.8 Pressure transducer

The transducer senses the actual system pressure.
Output signal [mA] 4 to 20

Power supply [V] UB=DC 10 to 30
Permissible load [Ohm] RA= (UB [V] --- 10 V) / 0.02 A
Tab. 73 Pressure transducer technical specification
Fig. 37 Pressure transducer
1 Connecting cable
2 Tecalan pipe to measuring point 1/4”
13 --- 100
Annex
Electrical connection
Fig. 38 Terminal assignment pressure transducer
A Power supply
B Interpretation/display
Trouble shooting
Fault Possible cause Corrective measure

No output signal. No power feed, Wiring break. Check power feed and wi-
ring, replace any defective
parts.
Transducer wrongly connec- Check power feed and wi-
ted. ring, replace any defective
parts.
No input pressure. Check pressure line.
Electronic fault due to exces- Contact KAESER service.
sive supply voltage or extra-
neous voltage.
Output signal does not Inlet channel blocked. Carefully clean inlet channel
change with changing and throttle screw, making
pressure. sure not to damage the dia-
phragm.
Electronic fault due to exces- Contact KAESER service.
sive supply voltage or extra-
neous voltage.
Pressure overloading. Contact KAESER service.
Output signal remains too Electronic fault due to exces- Contact KAESER service.
high with changing pres- sive supply voltage or extra-
sure. neous voltage.
Tab. 74 Trouble shooting pressure transducer
13 --- 101
Annex
13.4.9 Pressure differential switch

The pressure differential switch monitors the degree of clogging of the inlet filter.
The switch is triggered by pressure differential. Falling below or rising above the set value
causes the current flow to switch on, switch off or changeover according to how the switch
is connected.
Max. working pressure [mbar] 500

Pressure differential, adjustable [mbar] 2.5 to 50
(Factory set at 35)
Voltage [V] ∼ (AC) eff., min. 10
∼ (AC) max. 250
=(DC) min. 12
=(DC) max. 48
Nominal current [A] ∼ (AC) 10
Currente on contact ∼ (AC) eff., min. 20 mA
∼ (AC) max. 6 A, cosϕ = 1
∼ (AC) max. 3 A, cosϕ = 0.6
=(DC) min. 20 mA
=(DC) max. 1 A
Ambient temperature [˚C] ---15 to +70
Dimension LxWxH [mm] 82x47x82
Installation vertical
Sensor connection Pipe ends over which 4 mm hoses are pus-
hed and secured with ties or clamps.
Tab. 75 Pressure diferential switch technical specification
Pressure connection
Fig. 39 Pressure differential switch connection
1 Connection to lower pressure 3 Inlet silencer

2 Connection to higher pressure 4 Filter
13 --- 102
Annex
Electrical connection
Fig. 40 Pressure differential switch connection
Switch function
Fig. 41 Switch function
Rising pressure: 1 NC opens, 2 NO closes

Falling pressure: 1 NC closes, 2 NO opens
13 --- 103

BB53C EMR#2182794 Manual

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SERVICE MANUAL

KAESER KOMPRESSOREN GmbH

1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

2 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 26

3.8 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33

4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 35

5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 41

7 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44

9 Fault Finding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49

11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 61

12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . . 12 --- 69

Fig. 1 Location of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 33

Tab. 1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

Tab. 47 Installation conditions checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45

1 Regarding this Document

1.1 Handling the Document

1.2 Further Documents

1.4 Symbols and Identifications

1.4.1 Warning notices

Here is a notice warning of danger.

DANGER Here are consequences of ignoring the warning notice.

Signal word Meaning Consequences of ignoring the warning

1.4.2 Other notices and symbols

This symbol identifies environmental protection measures.

This symbol refers to particularly important information.

Power Frame size Motor

2.2 Ambient Conditions

2.3 Sound Pressure Level

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

2.4 Motors and Capacity

2.4.1 Drive motor

Rated power [kW] * 1.5 --- 15

2.4.2 Fan motor sound enclosure

Rated voltage [V] 230/400 230/400 290/500

Rated voltage [V] 208/360 230/400 266/460 277/480 333/575

Rated voltage [V] 230

Rated voltage [V] 115 230

2.5 Design Data

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

Guide values for 50 Hz / 400 V

Guide values at 60 Hz / 400 V

2.6 Lubricating Oil

2.6.1 Recommended lubricant

OMEGA OMEGA OMEGA OMEGA

2.6.2 Lubricating oil capacity

Drive---end [l] 0.15 ± 15 %