"SPECIFIC" USE AND
MAINTENANCE MANUAL
Screw compressors models:
KA 2-3-4-5-6-7 PLUS
Edition : 01 – 09/2015
(Translation of the original manual)
COMPLETING THE "GENERAL" USE AND MAINTENANCE MANUAL
Gardner Denver Srl
Via Tevere, 6
21015 Lonate Pozzolo
ITALY
EN
INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
CONTENTS
Page
1. TECHNICAL CHARACTERISTICS .................................................................................................................. 4
2. PERFORMANCE............................................................................................................................................... 5
3. OVERALL DIMENSIONS - WEIGHTS KA2-5 .................................................................................................. 6
4. OVERALL DIMENSIONS - WEIGHTS KA6-7 PLUS ....................................................................................... 7
5. MAINTENANCE PROGRAM ............................................................................................................................ 8
6. AIRBASIC 2 ELECTRONIC CONTROL UNIT ............................................................................................... 10
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
BEFORE PERFORMING ANY
OPERATION ON THE MACHINE IT
IS OBLIGATORY TO READ ALL
THE INFORMATION IN THE
"GENERAL" USE AND
MAINTENANCE MANUAL
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
1. TECHNICAL CHARACTERISTICS
1.1. General data
COMPRESSIBLE GAS TYPE AIR
SUCTION PRESSURE BAR (A) 1 (ATMOSPHERIC)
COVERED
INSTALLATION ENVIRONMENT TYPE
NOT POTENTIALLY EXPLOSIVE
LIMIT AMBIENT TEMPERATURE ºC MAX +40 / MIN +1
WORKING TEMPERATURE ºC 50-65 + AMBIENT TEMP.
AIR OUTPUT TEMPERATURE ºC 10-20 + AMBIENT TEMP.
AIR OUTPUT TEMPERATURE FOR
ºC 40-50 + AMBIENT TEMP.
MODELS < 5.5kW
OIL RESIDUE CONTENT PPM 2-3
LIMIT AMBIENT HUMIDITY % 80
MAX ALTITUDE m 1000
ELECTRICITY SUPPLY Volt / Hz / A SEE PLATE
TYPE OF OPERATION HOURS 24 / 24
MAX. STARTS/HOUR N 6
1.2. Fuse table
Fuse type AgL or equivalent.
50 Hz 60 Hz
kW 230 V 400 V 220 V 380 V 460 V
2,2 16 8 16 8 8
3 16 10 16 10 10
4 20 16 20 16 10
5 32 20 32 20 16
7,5 32 20 32 20 20
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
2. PERFORMANCE
SOUND
COMPRESSOR ACTUAL AIR FLOW MAXIMUM
MOTOR POWER PRESSURE
TYPE RATE * PRESSURE LEVEL **
KA kW HP m3 / min m3 / h BAR dB(A)
2
2,2 3 0,205 12,3 10 61
MONOFASE
2 2,2 3 0,24 14,4 10 61
3 3 4 0,36 21,6 10 61
4 4 5,5 0,53 31,8 10 62
5 5,5 7,5 0,67 40,2 10 66
0,92 55,2 10 68
6 7,5 10
0,80 48 13 68
1,05 63 8 67
7 PLUS 7,5 10 0,93 55,8 10 67
0,74 44,4 13 67
* Air flow rate measured according to standards ISO 1217, ed.4, ANNEX E – 2009 and test code /
Pneurop/Cagi PN 2 CPTC2 at the following working pressure: 7 bar versions at 7,5 bar; 9 bar versions
at 10 bar; 12 bar versions at 13 bar.
** Sound pressure level measured according to standards ISO 2151 and ISO 3744 at 1 m distance in
a free field.
WARNING: in particular indoor installation environments, the noise may increase by as much as 6÷10
dB(A) due to sound reflections against the walls.
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
3. OVERALL DIMENSIONS - WEIGHTS KA2-5
A B C
kW 2,2-3-4-5,5 / 200 1450 1355 600
kW 2,2-3-4-5,5 / 270 1540 1400 600
kW 2,2-3-4-5,5 / 500 1950 1520 680
200 LT. 270 LT. 500LT. COOLING AIR FLOW
kW 2,2 106 ----- ----- ----- RATE
kW 3 106 ----- ----- ----- kW 2,2-3-4 : 0,1 m3/s ;
kW 4 106 ----- ----- ----- 30 Pa
kW 5,5 119 ----- ----- ----- kW 5,5 : 0,2 m3/s ;
kW 2,2 ----- 166 191 ----- 50 Pa
kW 3 ----- 166 191 ----- THREE-PHASE
kW 4 ----- 166 191 251 ELECTRIC LINE
Kg kW 5,5 ----- 179 204 264 INPUT
kW 2,2 ----- 185 210 ----- MONOFAS SINGLE-
kW 3 ----- 185 210 ----- PHASE ELECTRIC
kW 4 ----- 189 214 274 LINE INPUT E
kW 5,5 ----- 202 227 287 COMPRESSED AIR
OUTPUT
RISKS LABEL
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
4. OVERALL DIMENSIONS - WEIGHTS KA6-7 PLUS
A B C
kW 7,5 / 270 1540 1560 600
kW 7,5 / 500 1950 1635 680
270 LT. 500LT. COOLING AIR FLOW
RATE
KA6 145 ----- -----
kW 7,5 : 0,3 m3/s ; 50 Pa
KA7PLUS 148 ----- -----
THREE-PHASE
ELECTRIC LINE INPUT
KA6 ----- 230 290
SINGLE-PHASE
ELECTRIC LINE INPUT
Kg KA7PLUS ----- 233 293
COMPRESSED AIR
OUTPUT
KA6 ----- 253 313
RISKS LABEL
KA7PLUS ----- 256 316
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
5. MAINTENANCE PROGRAM
Maintenance intervals for versions KA2-5
KIT
Advanced
Standard
Operation Job interval
Basic
Tubi
Check autom. condensate discharger
1 gg
(optional)
Discharge oil separator condensate 1 sett.
Check oil level 1 sett.
Check oil leaks 500 h
Check belts 500 h *
Clean radiator 1500 h
Clean inside 1500 h
Tighten electrical connections 1500 h *
x x x Change air filter 1500 h *
x x x Change oil filter 1500 h *
Grease motor bearings n.a.
1500 h
Change oil *
(max 1 anno)
Clean recovery nozzle 1500 h *
x x Change oil separator filter 3000 h *
x x Thermostatic valve kit 3000 h *
x x N/R valve 3000 h *
x x Tank cap gasket 3000 h *
Check:1 year
Safety valve Change: 2 *
years
6000 h
Change belts *
(max 4 years)
x Suction valve kit 6000 h *
x Minimum pressure valve kit 6000 h *
6000 h
x Change oil pipes *
(max 6 years)
Change screw seal ring 9000 h *
Change motor bearings 12000 h *
Change fan motor n.a.
Change SCREW bearings ---
NOTE: A label "Legend Maintenance" is applied to models without controller, as a
reminder of the maintenance program to follow.
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
Maintenance intervals for versions KA6-7 PLUS
KIT
Advanced
Standard
Operation Job interval
Basic
Tubi
Check autom. condensate discharger
1 gg
(optional)
Discharge oil separator condensate 1 sett.
Check oil level 1 sett.
Check oil leaks 500 h
Check belts 500 h *
Clean radiator 1500 h
Clean inside 1500 h
Tighten electrical connections 1500 h *
x x x Change air filter 1500 h *
x x x Change oil filter 1500 h *
Grease motor bearings n.a.
1500 h
Change oil *
(max 1 year)
Clean recovery nozzle 3000 h *
x x Change oil separator filter 3000 h *
x x Thermostatic valve kit 3000 h *
x x N/R valve 3000 h *
x x Tank cap gasket 3000 h *
Check:1 year
Safety valve Change: 2 *
years
Change belts 6000 h *
x Suction valve kit 6000 h *
x Minimum pressure valve kit 6000 h *
12000 h
x Change oil pipes *
(max 6 years)
Change screw seal ring 12000 h *
Change motor bearings 12000 h *
Change fan motor n.a.
Change SCREW bearings ---
N.B.: THE OPERATIONS MARKED (*) MAY BE CARRIED OUT ONLY BY GARDNER
DENVER SERVICE PERSONNEL
5.1 General indications on the oil change intervals
(for further details, see the control unit manual)
The recommended oil change intervals are listed below:
AEON 9000 SP
Compressor AEON 3000 (type F 2105) AEON 6000 FG
(SYNTHETIC)
Temperature Change interval Change interval
Change interval
70 – 87°C 3.000 h 4.000 h 6.000 h
88 – 92°C 1.500 h 2.000 h 6.000 h
≥ 93°C 500 h 1.000 h 3.000 h
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
6. AIRBASIC 2 ELECTRONIC CONTROL UNIT
The control panel is mounted on the compressor. It is used to operate the compressor and observe system
status by using the LCD display, status LED indicators and buttons.
The control panel displays a comprehensive overview of the compressor status and allows access to
operational parameters.
1 2
AirBasic 2 control panel
1. Display: indication of air pressure
2. Lamps: 3 green LEDs
3. Controls: 4 push-buttons :
Switches ON the compressor
Switches OFF the compressor
Oil temperature display
Alarms reset
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
4. Legenda display :
Alarm oil temperature
Alarm high temperature
Motor thermal overload relay trip
Phase inversion/phase loss
General maintenance pre-alarm hours
6.1 Display
When the compressor is powered, the display on the controller shows the “OFF” message.
If a remote control is connected to the remote START/STOP input and its contact is open, that is, in a STOP
condition, the display shows the “---” message.
In normal operation, with pressure transducer, the controller display shows the plant pressure; pushing the
TEMP/PROGR button it is shown the oil temperature, pushing it again or elapsed 10 s, on the display, it is
shown the pressure value. In operation mode, with the pressure switch, it is shown the only value of oil
temperature; the visualization of the pressure is disabled.
Note: The AirBASIC 2 controller display can only show up to 3 digits. Numbers with 4 or 5 digits are
indicated by the illumination of LEDs x10 or x100, which are called 10 multiplying factor and 100
multiplying factor respectively. The following examples show how the LEDs work.
Display examples
Value to be Display
Example No. LED x10 LED x100
displayed shows
1. 697 697 OFF OFF
2. 6970 697 ON OFF
3. 69700 697 OFF ON
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INSTRUCTIONS MANUAL KA 2-3-4-5-6-7 PLUS
6.2 Button functions
ON:
switches on the compressor
permits to increase the value on the display during the programming
OFF:
switches off the compressor
permits to decrease the value on the display during programming
RESET:
resets alarms
resets maintenance hours when the compressor is switched off
shows the working hour when the compressor is switched on
TEMP/PROGR:
permits to enter in parameters programming mode when the compressor is switched off
permits to show the oil temperature when the compressor is switched off only when the pressure
transducer is used
6.3 Indicator functions
x10: LED (green) indicates that the 10 multiplying factor is active.
x100: LED (green) indicates that the 100 multiplying factor is active.
( / ), steadily on: LED (green) indicates load operation mode.
( / ), flashing with regularity: LED (green) indicates unload operation mode.
( / ), flashing with two consecutive impulses : LED (green) indicates that the compressors is ready to start
after stopping and elapsed the unload time .
6.4 Note:
For more detailed instructions, refer to the user manual of the AIRBASIC 2 control unit.
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