Kaeser Service Manual

 

SERVICE MANUAL Screw Compressor Model: CSD No.: 9.5700.02E

Manufacturer:

KAESER KA ESER KOMPRESSOREN GmbH 96410 Coburg   PO Box 2143   GERMANY   Tel. + 49 --- (0) (0)9561 9561 --- 6400   Fax + 49-49---( -(0)9561 0)9561 ---6 -640130 40130  

http://www.kaeser.com

 

 

 

 

Contents Chapter --- page

1

2

Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2

Hand ling the Doc ument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1 Further Do c uments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.3 1.4 1.4.1 1.4.2

Cop yrig ht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symb ols and Identific atio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning no tic es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Misc ellaneo us no tic es and symb ols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.7 2.7.1 2.7.2 2.8 2.8.1 2.8.2 2.9 2.9.1 2.9.2 2.10

3

1 --- 1

2 --- 3

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temp erature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amb ient Co nditio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . So und Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moto r and Perfo rmanc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comp resso r moto r: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Mo to r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coo ling o il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re Rec o mmend ed c o o ling o il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coo ling Oil Vo lumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Po wer sup p ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Po wer sup p ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Po Po wer sup p ly spec ific atio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water c oo ling (op tio n K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Desig n d ata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coo ling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Heat Rec o very (o ption W2 / W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 --- 1 1 --- 1 1 --- 1 1 --- 2

2 --- 3 2 --- 3 2 --- 4 2 --- 4 2 --- 4 2 --- 4 2 --- 4 2 --- 5 2 --- 5 2 --- 5 2 --- 6 2 --- 6 2 --- 6 2 --- 6 2 --- 8 2 --- 8 2 --- 8 2 --- 9

3 --- 11

3.1

Correc t Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11

3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.6 3.7 3.7.1 3.7.2 3.8

Inc orrec t Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Us User’s Respo nsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Devic es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dang er fro m elec tric c urrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dang er fro m released spring fo rc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dang er fro m released c o mpressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further d angers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Symbo ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emerg enc ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coo ling o il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enviro nmental Pro tec tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 3 3 3 3 3 3 3 3

--- 11 --- 11 --- 12 --- 12 --- 12 --- 13 --- 13 --- 13 --- 14 --- 14 --- 14 --- 14 --- 14

i

 

Contents Chapter --- page

4

5

6

7

Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 --- 15

4.1

Mac hine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

4.1.1

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

4.1.2

Func tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

4.2 4.2.1

Op tio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17 Mac hine mounting s (o p tio n H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

4.2.2

Coo ling air filter mats (op tio n K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

4.2.3

Water c oo ling (op tio n K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

4.2.4

Heat rec o very . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

4.3

Op erating States and Contro l Mo d es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18

4.3.1

Op erating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18

4.3.2

Ta Tasks of the c o ntroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18

4.3.3

Contro l Mo d es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18

4.3.4

Mod ulating c o ntrol (o p tio n C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19

4.4

Safety Devic es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19

4.5

SIGMA CONTROL Keys and Ind ic ato rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20

Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . .

5 --- 22

5.1

Amb ient Co nditio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 22

5.2

In I nstallatio n Co nditio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 22

5.2.1

Plac e of installation and sp ac e req uired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 22

5.2.2

Ventilatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 23

5.2.3

Op erating in a c o mpressed air netwo rk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 --- 25

6.1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 25

6.2

Rep ort any Transpo rt Damag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 25

6.3

Install the Co mpressed Air Co nnec tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 25

6.4

El Elec tric al Co nnec tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26

6.5 6.5.1

Op tio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26 Mac hine fixing (o ptio n H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26

6.5.2

Water c oo ling c o nnec tio n (o ptio n K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26

6.5.3

Heat rec o very system c o nnec tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27

Initial Start --- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 --- 29

7.1

Befo re Initial Start --- up (o r Rec ommissio ning) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

7.2

Chec k Installation and Op erating Cond itio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

7.3

Setting the o verlo ad protec tion c ut --- out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

7.4

Moto r Pro tec tio n Switc h Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30

7.5

Po ur Co oling Oil into the Inlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30

7.6

Chec king Direc tio n o f Rotatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31

7.7 7.8

Initial Start --- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31 Setting Network Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31

ii

 

Contents Chapter --- page

8

9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 --- 32

8.1 8.1.1

Switc hing On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 32 Switc hing on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 32

8.1.2 8.1.3 8.2 8.3 8.4 8.5 8.5.1 8.5.2

Auto matic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switc hing off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switc hing Off in an Emerg enc y and Switc hing On Ag ain . . . . . . . . . . . . . . . . . Remote On and Off Switc hing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switc hing on and off with the Clo c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ac k kn no wl wled gi ging and Resetting Warning and Alarm Messag e es s ............. Re Resetting alarm messag es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re Resetting warning messag es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Event Recognition and Fault Rectification . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3

8 8 8 8 8 8 8 8

--- 32 --- 33 --- 33 --- 33 --- 34 --- 34 --- 34 --- 35

9 --- 36

Alarms (mac hine shut --- d own, red LED b link ing) . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36 Warning Messag es (yellow LED b link ing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41 Misc ellaneo us events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 44

10 M aintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 --- 46

10.1 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.3 10.3.1 10.3.2 10.3.3 10.4 10.5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenanc e Sc hedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting maintenanc e interval c ounters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reg ular maintenanc e wo rk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil c hange intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reg ular servic e work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coo ler Maintenanc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air c o oling (o ption K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter mat maintenanc e (o ption K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water c oo ling maintenanc e (o p tion K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Heat Rec o very Maintenanc e (op tio n W2 / W3) . . . . . . . . . . . . . . . . . . . Ai Air Filter Maintenanc e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 10 10 10 10 10 10 10 10 10 10 10

--- 46 --- 47 --- 47 --- 48 --- 48 --- 49 --- 50 --- 50 --- 50 --- 51 --- 52 --- 52

10.6 10.7 10.8 10.9 10.10 10.10.1 10.10.2 10.11 10.12 10.13 10.14 10.15

Filter mat maintenanc e (c o ntro l c ab inet ventilato r) . . . . . . . . . . . . . . . . . . . . . . . Elec tric mo to r maintenanc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ch Chec king the Co upling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Venting the Mac hine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec king and To pp ing up the Coo ling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec k c oo ling o il level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top p ing up the c oo ling o il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ch Chang ing the Co o ling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter maintenanc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec king the Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chang ing the Oil Sep arato r Cartrid ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lo gg ing Maintenanc e Wo rk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 10 10 10 10 10 10 10 10 10 10 10

--- 53 --- 54 --- 55 --- 56 --- 57 --- 57 --- 58 --- 60 --- 63 --- 64 --- 65 --- 67

iii

 

Contents Chapter --- page

11 Spares, Operating M aterials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 --- 68

11.1 11.2

No te the namep late . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 68 Ordering Maintenanc e Parts and Op erating Materials . . . . . . . . . . . . . . . . . . . . 11 --- 68

11.3 11.4 11.5

Maintenanc e Co ntrac t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 68 Servic e Add resses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 68 Sp are Parts for Servic e and Rep air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 68

12 De ----- c co ommissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . .

12 --- 75

12.1

De --- c ommissio ning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 75

12.2 12.3 12.4 12.5

Pac k ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sto rag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transp orting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disp o sal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 12 12 12

---------

75 75 76 76

13 --- 77

13.1 13.2

Confo rmity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 77 Di D iag rams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 77

13.2.1 13.2.2 13.2.3 13.2.4

Pipeline and instrument flo w d iag ram (P&I diagrams) . . . . . . . . . . . . . . . . . . . . Pipeline and instrument flo w d iag ram (o p tio n C1) . . . . . . . . . . . . . . . . . . . . . . . Dimensio nal d rawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elec tric al diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 13 13 13

---------

77 83 89 95

iv

 

Directory of Illustrations Chapter --- page

Fig . 1 Fig . 2 Fig . 3 Fig . 4 Fig . 5

Cab inet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air --- c o o led mac hine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co oling air filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water c o oling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal heat rec o very . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 4 4 4

--- 15 --- 16 --- 17 --- 17 --- 18

Fig . 6 Fig . 7 Fig . 8 Fig . 9 Fig . 10 Fig . 11 Fig . 12 Fig . 13 Fig . 14 Fig . 15

SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGMA CONTROL ind ic ato rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installatio n rec o mmend atio n, dimensio ns [ m mm m] . . . . . . . . . . . . . . . . . . . . . . . . . . Co mp ressed Air Connec tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water c o oling c onnec tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat rec o very . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet valve o il filling p ort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co up ling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switc hing On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switc hing o ff in an emerg enc y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 5 6 6 6 7 7 8 8

--- 20 --- 21 --- 23 --- 25 --- 27 --- 28 --- 30 --- 30 --- 32 --- 33

Fig. 16 Fig . 17 Fig . 18

Ack ckno nowl wle edgi dging and Resettin tting g Warni rning and Alarm Messa sage ges s . . . . . . . . . . . . . . . 8 --- 34 Cleaning the c oo ler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50 Co oler filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51

Fig . 19 Fig . 20 Fig . 21 Fig . 22 Fig . 23 Fig . 24 Fig . 25 Fig . 26 Fig . 27 Fig . 28 Fig . 29 Fig . 30 Fig . 31

Air filter maintenanc e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co ntrol c ab inet ventilato r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co mp resso r mo tor maintenanc e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec king the Co up ling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilate the mac hine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec k c o oling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To pp ing up the c o oling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Coo ling Oil, Oil Separator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Coo ling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Oil Sep arato r Cartrid g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transp o rt b y fork truc k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transp o rt b y lifting c radle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 10 10 10 10 10 10 10 10 10 10 12 12

--- 52 --- 53 --- 54 --- 55 --- 57 --- 58 --- 59 --- 60 --- 62 --- 63 --- 65 --- 76 --- 76

v

 

Table Directory Chapter --- page

Tab. 1 Tab. 2 Tab. 3 Tab. 4 Tab. 5

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Op tio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mac hine weig hts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mac hine temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amb ient Cond itio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 2 2 2 2

-----------

3 3 3 3 4

Tab. 6 Tab. 7 Tab. 8 Tab. 9 Tab. 10 Tab. 11 Tab. 12 Tab. 13 Tab. 14 Tab. 15

Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co mp resso r mo tor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan moto r d ata (o p tion K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan moto r d ata (o p tion K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rec o mmend ed c oo ling o il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co oling oil vo lumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sup p ly 230V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sup p ly 400V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sup p ly 230V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 2 2 2 2 2 2 2 2 2

--- 4 --- 4 --- 5 --- 5 --- 5 --- 6 --- 6 --- 7 --- 7 --- 7

Tab. 16 Tab. 17 Tab. 18

Sup p ly 380V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7 Sup p ly 440V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7 Sup p ly 460V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

Tab. 19 Tab. 20 Tab. 21 Tab. 22 Tab. 23 Tab. 24 Tab. 25 Tab. 26 Tab. 27 Tab. 28 Tab. 29 Tab. 30 Tab. 31

Water ater cooling design design data: data:   T= 10 K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water ater cooling design design data: data:   T= 30 K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co oler spec ific atio n; water c oo ling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Co oling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Quality Sp ec ific atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General spec ific atio n o f the heat exc hang er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flo w rate and heat availab le (op tio n W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flo w rate and heat availab le (op tio n W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insp ec tio n sc hed ule fo r Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGMA CONTROL ind ic ato rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec klist, installatio n c o nd itions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 --- 8 2 --- 8 2 --- 8 2 --- 9 2 --- 9 2 --- 10 2 --- 10 2 --- 10 3 --- 12 4 --- 21 4 --- 21 5 --- 24 7 --- 29

Tab. 32 Tab. 33 Tab. 34 Tab. 35 Tab. 36 Tab. 37 Tab. 38 Tab. 39

Alarm messages and ac tio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning messag es and ac tio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Misc ellaneo us events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reg ular maintenanc e work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil c hang e intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reg ular servic e wo rk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenanc e lo g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mac hine maintenanc e parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 --- 40 9 --- 44 9 --- 45 10 --- 48 10 --- 48 10 --- 49 10 --- 67 11 --- 68

 

 

vi

 

Regarding this Document 1

Regar egardi din ng this Docu Docum ment ent

1.1 1. 1

Ha Han ndlin dling g the the Do Docu cum men entt 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 from the machine mac hine nameplate nameplate in the table in chapter 2 ’Technical ’Technical Specifications’.

 

1.2 1. 2

Furth rther Do Docu cum men ents ts Included with this Service Manual are documents intended to assist in safe and sure operation of the machine:  

 

 

 

certificate of acceptance / operating instructions for the pressure vessel manufacturer’s manufacture r’s d ecla eclaration ration or declaration declaration of conformity in accordance with applicable applicable directives SIGMA CONTROL Service Manual Make sure all all do cuments are to hand hand and their contents understood.

Request the supply of any missing documents from KAESER. Make sure you give the data from the nameplate.

1 .3

Copyright This This servi service ce manual is copyright protected. Queries Queries regarding regarding use or duplication duplication of the documentation should be referred to KAESER. Correct use of information will be fully supported.

1.4

Sy Symb mbol ols s an and d Ide Iden nti tifi fica cati tion ons s

1.4.1 1.4.1

War arni ning ng no noti tice ces s Here is a notice warning of danger. DANGER

Here are consequences of ignoring the warning notice. The word ’Danger’ indicates that death or severe injury can result from ignoring the notice.  

Always read and diligently comply with warning notices.

Danger levels Warning notices indicate three levels of danger identified by the signal word under the dangerr symbol. dange

Signal word DANG DA NGE ER

Mea Meaning Warns rns of immi immine nent nt th thre reaatening danger

WAR ARNIN NING G

Warns arns of possible possible threate threate-ning danger

CAUT CA UTIO ION N

Warns rns of a possi possibl bly y dangerous situation

Con Consequences of ignoring the warning Death or severe injury or serious damage to the machine is possible Death or severe injury or serious damage to the machine is possible Light injury or slight damage possible

1 --- 1

 

Regarding this Document 1.4.2 1.4 .2

Miscell Miscellan aneou eous s no noti tices ces an and d sy symbo mbols ls  

Here is a task to be carried out.

This symbol identifies environmental protection measures.

This indicates important information.

1 --- 2

 

Technical Specification 2

Tech echnic ical al Spec Specif ific icat atio ion n Model and important technical information is to me found on the machine nameplate. Please transfer data from the nameplate. Model Materiall no. Materia no . Serial no. Serial Year of manufacture Rated power Motor speed Maximum working pressure Ambient temperature Tab. 1 Namep la late   A summary of the included options helps helps to relate relate the service manua manuall information information to your machine. Please enter details of options.

Option

Code

Air c o oling Water c oo ling Coo ling air filter mat Ad d itio nal fan fo r fitted exhaust d uc ting Mac hine mounting s Prepared for heat rec o very

K1 K2 K3 K4 H1 W1

Internal heat recovery   T= 25K Internal heat recovery   T= 55K Mod ulating c o ntro l Transformer power supply for refrigeration dryer Tab. 2 Op tio ns    

 

2 .1

Exists

W2 W3 C1 T2

Weight Maximum weights are shown. Actual weights of individual machines are dependent on equipment fitted. Weig ht [ kg ] Tab. 3 Ma Mach chiine wei weigh ghtts 

2.2 2. 2

C SD 82 1300

C SD 1 0 2 1350

C SD 122 1400

C SD 82 3

C SD 1 0 2 3

C SD 122 3

75 --- 100

75 --- 100

75 --- 100

110

110

110

Tem empe perrat atu ure Minimum cut ---in temperature [˚C] Typical airend discharge temperature pera ture during during operation [˚ C] Max. airend discharge temp. (automatic (automa tic shut-shut---down) [˚ C] Tab. 4 Machi Machine ne te temp mper era atu ture res  s 

2 --- 3

 

Technical Specification 2.3 2. 3

Ambien bientt Co Con nditi dition ons s C SD 82 1000 3 – 45

Maximum elevatio n [ m] Amb ient temp erature [ ˚ C]

C SD 1 0 2 1000 3 – 45

C SD 122 1000 3 – 45

Inlet air / cooling air tempera3 – 45 3 – 45 tur ture e [˚ C] Maximum relative inlet air hu100 100 midity midi ty at 31 ˚ C [%] Maximum relative inlet air hu50 50 midity midi ty at 45 ˚ C [%] * Higher elevation permissible only after consultation with the manufacturer Tab. 5

2 .4

3 – 45 100 50

Ambi mbien entt Con ondi dittion ons  s 

Pressure See nameplate for maximum working pressure

Maximum working pressu pressure re [bar]

Tab. ab. 6

2.5 2. 5

Blow---off setting of the pressure relief valve [bar]

C SD 82 8 11,5 11 14 15 16 Press ressur ure e reli relief ef val alv ve se sett ttin ing  g 

C SD 1 0 2 11,5 14 16

C SD 122 11,5 14 16

So Sou und Pr Pres essu sure re Lev evel el Operational state  

under load at rated speed, rated delivery and rated pressure.

Measuring conditions:  

Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance

So und p ressure level (50Hz) [ dB(A)] So und p ressure level (60Hz) [ dB(A)] Tab. 7 Sou ound nd Pre ress ssur ure e Lev Level 

2.6 2. 6

Mot Motor or an and d Pe Perf rfor orm man ance ce

2.6.1 2.6.1

Compr Compres esso sorr mo moto tor: r:

Rated po wer [ k W] Rated sp eed [ rp m] (50 Hz) Rated sp eed [ rp m] (60 Hz)

C SD 82 68 69

C SD 102 69 70

C SD 122 70 71

C SD 82 45 2965 3568

C SD 102 55 2965 3568

C SD 122 75 2978 3580

IP 55

IP 55

Enc losure p ro tec tio n IP 55 * Transfer data from motor nameplate to the table

2 --- 4

 

Technical Specification

Motor bearing greasing [o perating perating hours] Grease requirement, each bearing [g]*

CSD 82 2000

CSD 102 2000

CSD 122 2000

C SD 82 1,1 940 1120 IP 54

C SD 102 1,1 940 1120 IP 54

C SD 122 1,1 940 1120 IP 54

C SD 82 0,12 0,17 2500 2700 IP 54

C SD 102 0,12 0,17 2500 2700 IP 54

C SD 122 0,12 0,17 2500 2700 IP 54

* Transfer data from motor nameplate to the table Tab. 8 Compr ompres esso sorr moto motorr da data  ta 

2.6.2

Fan Mot Motor Air cooling (option K1)

Rated po wer [ k W] Rated sp eed [ rp m] (50 Hz) Rated sp eed [ rp m] (60 Hz) Enc losure p ro tec tio n Tab. 9 Fan moto motorr da data ta (opt (optio ion n K1)

Water cooling (option K2)

Rated po wer [ k W] (50 Hz) Rated po wer [ k W] (60 Hz) Rated sp eed [ rp m] (50 Hz) Rated sp eed [ rp m] (60 Hz) Enc losure p ro tec tio n Tab. ab. 10 Fan motor motor data data (opt (option ion K2)

2 .7

Cooling oil Ordering: see ’Spare Parts, Parts, Operating Materia Materials, ls, Service’ Service’ chapter chapt er 11.

2.7.1 2.7 .1

Recomm Recommen ended ded coo cooli ling ng oil oil The standard factory filling is SIGMA FLUID PLUS. SIGMA FLUID FGL/FGH is recommended for use in connection with foodstuff. mended A sticker showing the type o f oil filled filled is to be found near the oil separator separator filling port.

SIGMA IGMA FLUID PLUS

SI SIGM GMA A FLUID MOL MOL

SIGMA IGMA FLUID FGL Synthetic oil Specially for use in compressors where the air comes in direct contact with foodstuff. 

Desc rip tio n Appl pplica icati tion on::

Autho rizatio n

Synthetic o il Sta tand nda ard oi oill fo forr all applications except in connection with foodstuffs. Designed for high loading and long operational life. —

Mineral o il Standard oil for all applications except in connection with foodstuffs. Designed for light loading. —







 

USDA H–1, ap pro ved for the manufacture manufacture of fo odstuff packaging, meat processing and other food p rocessing. rocessing.

2 --- 5

 

Technical Specification SIGMA FLUID PLUS

SIGMA FLUID MOL

Viscosity at 40 ˚ C Viscosity at

70 (DIN 51562---1) 10.6 mm2 /s

44 (DIN 51562---1) 6.8 mm2 /s

SIGMA FLUID FGL 50.7 / 70 mm 2 /s (D 445; ASTM test) 8.2 / 10.4 mm 2 /s

10 100 0 ˚C Flash p o int

(DIN 51562---1) 260 ˚ C (DIN ISO 2592) 84 843 3 kg/m3 (DIN 51757) --- 39 39 ˚ C (DIN ISO 3016) 30 min (DIN ISO 6614)

(DIN 51562---1) 22 220 0 ˚C (DIN ISO 2592)  —

(D 445; ASTM test) 25 254 4 ˚C (D92; ASTM test) —

---33 -3 3 ˚ C (DIN ISO 3016)  —

 —



mm2 /s

Dens De nsit ity y at 15 ˚ C Pour po int Demulsibility at 54 ˚ C Tab. 11

2.7.2 2.7.2

mm2 /s





 

—

Recomm ecommen ende ded d coolin cooling g oi oil l 

Cooli Cooling ng Oi Oill Volu olumes mes C SD 82

C SD 102

To tal c harg e [ l] 28 28 Top---up volume [l] 4 4 (minimum --- maximum Ad d itio nal volume [ l] (op tio n W2) 4,7 4,7 Ad d itio nal volume [ l] (op tio n W3) 3,8 3,8 Additional Additi onal volume [l] (option W1) * * Input the additional additional volume corresponding to your heat recovery system. Tab. 12

2. 2.8 8



C SD 122 28 4 4,7 3,8

Coolin ooling g oi oill vol olum umes  es 

Power supply See electrical diagrams in chapter 13.2.4.

2.8. 2.8.1 1

Power ower supply pply 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 machine may only o nly be operated o perated with a neutral point earthed TN or TT three-three---p -phase hase supply.. An IT supply is not p ermitted. supply ermitted.

2.8.2 2.8 .2

Powe Powerr su suppl pply y sp speci ecifi ficat catio ions ns The following conductor cross---sections (multicore Cu) and fusing (HRC fuse slow blow) are given given acco rding to VD VDE E 0100, parts 430 and 523, for ambient ambient temperatures temperatures of 30 ˚ C. If other local conditions prevail (high temperature, non---standard cable laying or cable lengths above > 50 m) the cross---section should be checked and adjusted accordingly.

2 --- 6

 

Technical Specification 3 --- ph, 50Hz Rated power supply 230V   10%, 3 

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 13 Supply upply 230V 230V/3/ /3/50 50Hz  Hz 

C SD 82 200 4 x 95

C SD 102 224 4 x 120

C SD 122 -----

155

189

---

C SD 102 125 4 x 50 108

C SD 122 160 4 x 70 138

C SD 102 224 4 x 120 191

C SD 122 -------

C SD 102 125 4 x 50 115

C SD 122 160 4 x 70 147

C SD 102 125 4 x 50 102

C SD 122 160 4 x 70 124

C SD 82 100 4 x 35

C SD 102 125 4 x 50

C SD 122 160 4 x 70

81

98

119

3 --- ph, 50Hz Rated power supply 400V   10%, 3 

C SD 82 100 4 x 35 88

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 14

Supply upply 400V 400V/3/ /3/50 50Hz  Hz 

Rated power supply 230V   10%, 33 --- ph, 60Hz  

C SD 82 200 4 x 95 160

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 15

Supply upply 230V 230V/3/ /3/60 60Hz  Hz 

Rated power supply 380V   10%, 33 --- ph, 60Hz  

C SD 82 125 4 x 50 98

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 16

Supply upply 380V 380V/3/ /3/60 60Hz  Hz 

Rated power supply 440V   10%, 33 --- ph, 60Hz  

C SD 82 100 4 x 35 84

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 17

Supply upply 440V 440V/3/ /3/60 60Hz  Hz 

Rated power supply 460V   10%, 33 --- ph, 60Hz  

Pre --- fuse [ A] Supply [mm2] Co nsump tio n [ A] Tab. ab. 18 Supply upply 460V 460V/3/ /3/60 60Hz  Hz 

2 --- 7

 

Technical Specification 2.9 2. 9

Wat ater er co cool oliing (op (opti tion on K2)

2.9. 2.9.1 1

Des Design dat data Cooling water temperature rise 10 K C SD 82 70

Max. permissible discharge temperatur ture e [˚ C] Max. permissible inlet temperature 40 [˚C] Cooling water water volume [ m3 /h] 4,4 Water pressure d ro p [ bar] 1,2 Tab. ab. 19 Wat ater er cooling cooling design design data data:  :    T= 10 K 

C SD 102 70

C SD 1 2 2 70

40

40

5,4 1,7

6,3 2,4

C SD 102 70

C SD 1 2 2 70

20

20

1,8 0,5

2,1 0,5

 

Cooling water temperature rise 30 K C SD 82 70

Max. permissible discharge temperature [   C]  

20 Max. [   C] permissible inlet temperature Cooling water water volume [ m3 /h] 1,5 Water pressure d ro p [ bar] 0,5 Tab. ab. 20 Wat ater er cooling cooling design design data data:  :    T= 30 K   

 

Cooler specification specification Material o f manufac ture So ld er Maximum working pressure (cooling water end) [bar] UNsuitable c oo ling med ium

Tab. ab. 21

2.9.2 2.9.2

1.4401 Co p per 10 Seawater

Consult Kaeser before using cooling water solutions Coole Coolerr spe specif cifica icati tion; on; wate waterr cooli cooling  ng 

Cooli Cooling ng Water ater Qu Qual alit ity y Measures for cooling water treatment and filtration are essential and must be carried out. The addresses of companies specialising in the analysis of cooling water and supplying suitable equipment for the its treatment can be obtained obt ained from KAESE KAESER R on request. To avoid opera operating ting breakdowns from a c orroded or clogged c ooler, ooler, the c ooling water must meet certain minimum requirements: p H value Hard ness [ dH] Chlo rid e (Cl) [ mg /l] Free chlorine gas (Cl2) [ mg/l] Sulphate (SO3) [ mg /l] Disso lved iron (Fe) [ mg /l]

7.5 to 9 4,0 --- 8,5 < 150 < 1 < 1 < 0.2

2 --- 8

 

Technical Specification Hydrogen c arbonate arbonate (HCO3) [ mg/l] Sulphate (SO4) [ mg /l] HCO3 / SO 4 Electrical Ele ctrical c onductivity [   S/c m] Ammonia (NH3) [ mg /l]

 

 

Disso lved magnesium (Mn) [ mg /l] Disso lved aluminium (Al) [ mg/l] Nitrate (NO3), disso lved [ mg /l] Hydrogen sulphate (SO2) [ mg /l] Free aggressive carbon dioxide (CO2) [ mg /l] Glyc o l [ %] So lids (p artic le size) [ mm] Alge Tab. ab. 22 Cooli Cooling ng Wat ater er Qu Qual alit ity  y 

2.10

70 --- 300 < 70 > 1 10 --- 500 < 2 < 0,1 < 0,2 < 100 < 0,05 < 5 < 50 < 0,1 no t permissib le

Int Intern ernal al Heat Rec Recov overy ery (opt (option ion W2 / W W3) 3) A soldered, plate heat exchanger is installed for heat recovery. Generally water is used as the heat transfer medium. This must conform to the specification given below. The manufacturer should be consulted before another type of heat transfer medium is used.

Water Quality Specification p H value Hard ness [ dH] Chlo rid e (Cl)* [ mg /l] Free chlorine gass (Cl2) [ mg /l] Sulphate (SO3) [ mg /l] Disso lved iron (Fe) [ mg /l] Hydrogen c arbonate arbonate (HCO3) [ mg/l] Sulphate (SO4) [ mg /l] HCO3 / SO 4   Electrical Ele ctrical c onductivity [   S/c m] Ammonia (NH3) [ mg /l] Disso lved magnesium (Mn) [ mg /l] Disso lved aluminium (Al) [ mg/l] Nitrate (NO3), disso lved [ mg /l] Hydrogen sulphate (SO2) [ mg /l] Free aggressive carbon dioxide (CO2) [ mg /l] Glyc o l [ %] So lids (p artic le size) [ mm] Alge Tab. 23 Wat ater er Qua Qualility ty Specif pecificat ication  ion   

7.5 to 9 4,0 --- 8,5 < 150 < 1 < 1 < 0.2 70 --- 300 < 70 > 1 10 --- 500 < 2 < 0,1 < 0,2 < 100 < 0,05 < 5 < 50 < 0,1 no t permissib le

If the heat transfer medium outlet temperature is to be kept constant, the user must install an appropriate regulating device.

2 --- 9

 

Technical Specification Heat Exchanger Exchanger Specification Specification C SD 82 10

Maximum working pressure of the heat transfer medium [bar] Pressure d ro p [ bar] < 0,1 Plate material 1.4401 So ld er Cu Maximum permissible temperature of 100 the heat heat transfer transfer medium [ ˚ C] Tab. 24 Ge Gener neral al specificat specification ion of th the e hea heatt ex exchan changer  ger 

C SD 102 10

C SD 122 10

< 0,1 1.4401 C Cu u 100

< 0,1 1.4401 Cu Cu 100

K), Flow rate rate and heat capacity capacity by heat heating ing fro from m 45 ˚ C to 70 ˚ C (equival (equivalent ent to   T= 25 K), (option W2)  

C SD 82 Flow rate [m3 /h] 1,39 Max. heat c ap ac ity availab le [ kW] 40,3 Max. heat c ap ac ity availab le [ MJ/h] 145 Max. heat c ap ac ity availab le [ kc kc al/h] 34669 Tab. 25 Flow ra rate te an and d heat heat av avai aila lable ble (opti (option on W2)

C SD 102 1,70 49,4 178 42511

C SD 1 2 2 2,00 58,1 209 49940

K), Flow rate rate and heat capacity capacity by heat heating ing fro from m 15 ˚ C to 70 ˚ C (equival (equivalent ent to   T= 55 K), (option W3)  

C SD 82 Flow rate 0,63 Max. heat c ap ac ity availab le [ kW] 40,3 Max. heat c ap ac ity availab le [ MJ/h] 145 Max. heat c ap ac ity availab le [ kc kc al/h] 34669 Tab. 26 Flow ra rate te an and d heat heat av avai aila lable ble (opti (option on W3) [m3 /h]

C SD 102 0,77 49,4 178 42511

C SD 1 2 2 0,91 58,1 209 49940

2 --- 10

 

Safety and Responsibility 3

Safe Safetty an and d Respo espon nsibil ibilit ity y Disregarding this notice can result in serious injury!

The machine is made to the latest technical safety standards and acknowledged safety regulations. Nevertheless, Nevertheless, risk of injury and death death for the user and third parties and damage to the machine and and other p roperty can arise from its use. The The machine may only be used: used: when it is in technically technically perfect condition; for the purpose for which it is intended; and when all safety measures as detailed in the service manual are put into practice. In particular, any faults relating to safety must be rectified immediately.

3 .1

Correct Use The machine is intended solely for industrial use in generating compressed air. Any other use is considered incorrect. The manufacturer is not liable for any damages resulting from such unspecified use or application. app lication. The responsibility, in case, lilies es solely with the user user.. Correct use also includes compliance with the data contained in this manual. The machine may only be used in consideration of the installation conditions.

3. 3.2 2

Inc Incorrec ectt Use Untreated compressed air may not be used:  

 

3.3

as breathing br eathing air, air, for any process in which the air can come into contact with foodstuff.

Us User er’s ’s Re Resp spon onsi sibi bili liti ties es Personnel All Allow ow only specialists specialists or persons who have been trained trained or instru instructed cted o n this machine to carry out work o n the machine. machine. This This applies particularly particularly for:  

 

 

 

installation installa tion and initial start ---up -up,, maintenance and service work, repairs, inspections.

All Allow ow wo rk to be carried out on electrical equipment equipment only by a qualified qualified electrician electrician or trained personnel under the supervision of a qualified electrician, and according to electrical engineering regulations. Ensure that all persons working on the machine have read, understood and observe the safety safe ty ---relevant passages in the service manual. m anual. Give clear instructions on reporting faults and damage to the machine. Observe the relevant regulations during installation, operation, maintenance and repair of the machine. These are, for example, nationally applied European directives and/or valid national laws and safety and accident prevention regulations.

Adhere to inspection inspection schedules and accident prevention prevention rregulat egulations ions The machine is subject to local inspection schedules.

3 --- 11

 

Safety and Responsibility Operation in Germany:  

Recurring inspections in accordance with VBG 16 --- § 18

The The comp any (user) must ensure that recurring recurring inspe inspections ctions of safety safety devices on compressors with motor power greater than 0.5 kW are carried out by qualified persons. Inspection intervals of one year are generally sufficient.  

Oil change in accordance with VBG16 --- §17 Oil change as required but at least once a year. The oil need not be changed if analysis shows it to be still useable.  

Inspection schedule in accordance with operating safety regulations and with the strictestt acco rding to §1 strictes §15. 5.

I nspection Installation and equipping Inter Interna nall ins inspecti pection on

Schedule bef before ore initi tia al sta tarrt-t---up -up

ever every y 5 years years af after ter ins instal talla lation tion or the last inspection Stre trength gth tes test eve very ry 10 ye yea ars after ter ins nsta talllati lation on or the last inspection Tab. ab. 27 In Inspe spectio ction n schedul schedule e for Germ German any  y 

3. 3.4 4

I nspecting authority app ppro rov ved supe perrvisor ory y bo boa ard approved supervisory board approved supervisory board

Saf afet ety y Dev eviices 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 information on safety safety devices is containe contained d in chapter 4 ’Design ’Design and Function’, section 4.4 ’Safety ’Safety Dev Devices’. ices’.

3 .5

Hazards Fundamentals: observe the accepted safety regulations Observe safety regulations at all times when working on the machine. Examples of these are directives and national regulations concerning safety and accident prevention.

3.5.1 3.5 .1

Danger Danger from from elect electric ric cu curre rrent nt Electric shock can kill! DANGER

Touching electrically live components can cause serious injury or death.  

 

 

 

 

 

Isolate Isola te comp letely letely from the mains supply (all conduc tors) (switch off at the main isolator) Ensure Ens ure the supply cannot b e switched on again again (lock off). Check that no voltage is present. Only work on electrical components when they are voltage---free. Work carefully. Before switching on again ensure that:  

no one is working on the machine,

 

 

all panels are in place and secured, all access doors are closed.

3 --- 12

 

Safety and Responsibility Work o n the electrical equipment equipment may only be carried out by a qualifie qualified d electrician electrician or by instructed persons under the supervision of a qualified electrician. Before Bef ore the machine is switched on for the first time the user must provide and check measures to guard against electric shock by direct or indirect contact.

3.5.2 3.5 .2

Danger Danger from from rel releas eased ed sp sprin ring g force force Springs Sprin gs under tension tension or compression compression contain force. Uncontrolled Uncontrolled release release of this force can be life---threatening.

WARNING

There is considerable danger of injury or death from the release of spring sprin g force if sprin spring g --- loaded components are incorrectly incorrectly opened (dis( dismantled). Minimum pressure/check valves, pressure relief valves and inlet valves are under powerful spring loading.  

3.5.3 3.5 .3

Do not open (dismantle) valves.

Danger Danger from from rel releas eased ed com compre press ssed ed air Compressed air is a contained force. Uncontrolled release of this force can be life---threatening.

Compressed air can cause injury or death. WARNING

Serious Serious injury or d ea eath th c an result result from loosen loosening ing 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. De---pressurize all pressurized components and enclosures. Check all machine hose connectors with a hand---held pressure gauge to ensure that all read zero.

Extension or change to the compressed air supply system If a compressed air installation is changed or a new machine installed, check the blow---off capacity of the pressure relief valves on air receivers and pipelines. Any pressure relief vales of insufficient capacity must be replaced with larger models.

3.5.4 3.5.4

Fu Furt rthe herr da dan nge gers rs Handling cooling and lubricating fluids  

 

 

 

Avoid contact with skin and eyes. Do not inhale oil mist or vapour. Do not ea eatt o r drink while ha handling ndling cooling and lubrica lubricating ting fluids. Fire, open flame and smoking are strictly forbidden.

Welding When welding is taking place on or near the machine take adequate measures to ensure that no p arts of the machine or any oil vapours are ignite ignited d by sparks. sparks.

3 --- 13

 

Safety and Responsibility Spare parts The use of unsuitable parts may adversely influence the safe working of the machine. Use only genuine KAES KAESER ER spares for parts subject to pressure.

3.6 3. 6

Warn arning Sy Sym mbo bolls Beware of life-life---threatening electrical voltage. Do not touch electrical components; danger of electric shock. Before Bef ore opening, switch off at the main switch and lock off to secure aga against inst unwanted or accidental switching on. Warning of hot surface. Do not touch surface --- danger of burning. Wear long---arm garments (not synthetics such as polyester) and protective gloves. Beware --- machine starts automatically. Machine Machi ne can start start automa automaticall tically y or by remote sta start rt command. Before Bef ore opening the machine, swi switch tch off at the main switch and lock off to secure against unwanted or accidental switching on.  

 

 

 

 

 

3. 3.7 7

Emer erg gencies

3.7. 3.7.1 1

Fire Fire figh fighti tin ng Suitable extinguishing media:  

 

 

 

foam powder carbon dioxide sand or earth

Unsuitable or unsafe extinguishing media:  

3.7. 3.7.2 2

powerful water jet

Coo Cooling oil oil Skin contact:  

wash off immediately

Eye contact:  

rinse thoroughly with lukewarm water and seek medical assistance.

If necessary, necessary, request a c opy of the safety data d ata sheet for KAESER KAESER SIGMA SIGMA FLUID. FLUID.

3.8

En Env viron ironme ment ntal al Pr Prot otec ecti tion on Do not allow cooling oil to escape to the environment or into the sewage system. Store and dispose of operating materials and replaced parts in accordance with local environment protection protec tion regulations. Observe national regulations. regulations. This applies particularly to parts contaminated contaminated with cooling o il.

3 --- 14

 

Design and Function 4

Design and Function

4.1 4. 1

Ma Mac chine Ov Over erv view

4.1.1

Cab Cabinet

Fig . 1 1 2 3

Cabinet  

Con Contr trol ol cabine cabinett door  Latc h   Removabl emovable e panel  panel 

The cabinet serves various purposes:  

 

sound damping protection

 

cooling air flow control Safe and reliable operation can only be ensured with the cabinet closed. Latches are released by a key supplied with the machine. Access doors are hinged to swing open, removable panels must be lifted off.

4.1. 4.1.2 2

Functi ction Items in in brackets [ ] correspond to the Pipe and Instrume Instrument nt Flow Diagram Diagram (P & I Diagra Diagram) m) in chapter chapter 13.2.1. 13.2.1. An air---cooled machine serves to illustrate function.

4 --- 15

 

Design and Function

Fig. 2 1 2 3 4 5

Air---coole -cooled d machi machine  ne 

Inlet valve [ 2] Co upling [ 5] Drive moto r [ 3] Oil filter [ 10] Airen end d [4] 

6 7 8 9

Co ntro l c ab inet   Oil separato r tank [ 6]   Air filter [ 1]   Oil/air c o o ler [ 11/13]  

Compressor Atmospheric air is cleaned as it is drawn in through the filter (8). The air is then compressed in the airend (5). The airend is driven by an electric motor (3). Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the rotors themselves and between them and the airend casing. The cooling effect directly within the compression chamber ensures a low airend discharge temperature. Cooling oil is recovered from the c ompressed ompressed air in the oil separator separator tank (7) gives up its heat in the oil cooler (9). The oil then flows through the filter (4) and back to the point of injection. Air pressure within the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve maintains optimum oil temperature. Compressed air, freed of its oil content in the separator tank (7), flows through the minimum pressure/check valve (8) into the aftercooler (9). The minimum pressure/check valve ensures there is always sufficient air pressure to maintain cooling oil circulation. The The after aftercooler cooler brings down the compressed compressed air temperature temperature to 5 to 10 K above ambient. ambient. Most of the moisture carried in the air is removed in the aftercooler.

4 --- 16

 

Design and Function 4 .2

Options

4.2.1 4.2 .1

Machine Machine mount mountin ings gs (optio (option n H1) The machine mountings enable the machine to be anchored to the floor.

4.2.2 4.2 .2

Coolin Cooling g air filt filter er mats mats (optio (option n K3) Mats filter the cooling air and keep the cooler surface clean.

Fig. 3 1

4.2.3 4.2 .3

Coo oollin ing g air filter lter ma matts 

Cool Cooling ing ai airr filte filterr ma mat  t 

Water ater cooli cooling ng (opt (option ion K2) Plate heat exchangers in stainless steel are used for water---cooled machines.

Fig . 4 1 2

4.2. 4.2.4 4

Water co coo oling  

Oil c o o ler [ 11] Co mp mpressed air afterco coo o le ler [ 13 13]

3 4

C Co o oling water c onnec tio n   Co ol oling water con connecti ctio n  

Heat Heat re reco cov very ery Prepared for external heat recovery (option W1) Connections Conne ctions are provided and bridged. An external heat heat reco very system c an be retro ---fitted at any time.

Internal heat recovery (option W2 / W3) A plate heat exchanger (1) is installed for heat recovery.

4 --- 17

 

Design and Function

Fig. 5 1

Int nte erna nall he hea at rec ecov ove ery 

Plate late heat heat exchan exchanger ger [26] 

4.3

Ope Opera rati ting ng St Stat ates es an and d Co Cont ntro roll Mod Modes es

4.3.1 4.3.1

Oper Operat atin ing g stat states es There are three operating states:  

LOAD: the inlet valve is open. The airend delivers compressed air to the system. The drive motor runs under full load.

 

IDLING: The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the air system. The oil separator tank is vented. A small volume of air circulates through the bleed hole in the inlet valve, through the airend and back to the inlet valve via the venting valve. The The drive motor runs without load and draws little current.  

 

4.3.2 4.3 .2

STANDSTILL: The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the air system. The oil separator tank is vented. The The drive motor is stopped. PARTIAL LOAD (option C1): The proportional controller continuously varies the degree of opening of the inlet valve, and thereby the delivery rate of the compressor, in response and in proportion to the air demand. The airend delivers compressed air to the system. The The load and p ower consumption of the drive motor rises and falls with the air demand.

Tas asks ks of the the contro controll ller er Using Usin g the selected selected c ontrol mode, the controller switches the comp ressor ressor b etween etween its various operational states in order to maintain system pressure between the set minimum and maximum values. values. According to the individual individual compressed compressed air demand demand o ne of the various control modes availavailable will will provide the op timum duty cycle for the machine. machine.

4.3. 4.3.3 3

Con Contro roll Modes Modes The following control modes are available:  

 

 

DUAL VARIO QUADRO

DUAL In the DUAL DUAL control mode, the compressor is switched b ack and forth between between full load and idle to maintain system pressure between the set minimum and maximum values.

4 --- 18

 

Design and Function When the maximum pressure is reached the machine switches to IDLING. When the preset idling time  has  has elapsed the machine is switched to STANDSTILL. The shorter the  idling time  setting,  setting, the sooner and more frequently frequently the motor is stopped.

VARIO The VARIO control mode is an extension of DUAL control. The difference being that under DUAL control the idling time  is   is automatically increased or decreased corresponding to the increased or decreased switching frequency of the drive motor.

QUADRO In QUADRO control mode the machine switches from LOAD to IDLE during periods of high air demand and directly from LOAD to STANDSTILL during periods of low air demand. This mode of control requires two pre---set time periods: the running time  and  and the  idle/  standstill time . The shorter these time settings, the sooner and more frequently the motor is stopped.

4.3.4 4.3 .4

Modulat Modulatin ing g con contr trol ol (opt (optio ion n C1) The modulating control mode is an extension of DUAL control. The difference being that, in this mode, the d elivery elivery of the compressor is steplessly steplessly varied within the co ntrol range of the machine.  

Increasing air demand

The machine operates between PARTIAL LOAD and LOAD.  

Falling air demand

The machine operates between PARTIAL LOAD, IDLE RUNNING and STANDSTILL.

4. 4.4 4

Saf afet ety y Dev eviices The following safety devices are provided and may not be changed:  

 

 

EMERGENCY EMERG ENCY ST STOP OP button butt on The EMER EMERGENCY GENCY ST STOP OP button shuts down dow n the co mpressor immediately. The The motor remains still. The pressure system is vented. Pressure relief valve The pressure relief valve protects the system from excessive pressure. This is factory set. Housing and covers for moving parts and electrical connections. connections. Protection Prote ction from accidental contact.

4 --- 19

 

Design and Function 4.5

SIG SIGMA MA CON CONTR TROL OL Key eys s an and d In Indi dica cato tors rs

Fig. 6

Symbol

SIGMA CONTROL ke key ys 

Ite Item Description 1

ON (I)

Function Switc h the mac hine o n. Programmed operating mode is active.

2

OFF (0)

Switc h the mac hine o ff.

3

Ope Operati rating ng mode mode: Clock

Switching clock---control on and off.

4

Ope Operati rating ng mode mode: Remote control

The LED lights when the machine is under clock control. Switching Swi tching remote control on and off. The LED illuminates when the machine is under remote control. Toggles the machine mac hine between LOAD LOAD and IDLE. IDLE.

5

Ope Operati rating ng mode mode: LOAD /  IDLE    IDLE 

6

Arro w key

Sc ro lls d own menu.

Arro w key

Reduces Reduces a parameter value. value. Sc ro lls menu up .

Esc ap ap e

Increases a paramete p arameterr value. Returns to the next higher menu level.

7 8

Exits the edit mode without saving.

9

Retur eturn/e n/ente nter/s r/sav ave e key

Returns to the main menu when held down at least 10 seconds. Only affects affects the messa message ge in the third line of the display (12). Returns to the selected submenu. Saves and leaves the edit mode.

4 --- 20

 

Design and Function Symbol

Item Description 10

11

Events vents and and in info forrmation key

Acknowl cknowled edge ge (re(reset) key

Function Displays the event memory. Selection from every menu. Returns together with ’esc’ key (8). Acknowledges (re---sets) messages and resets the event memory (if permitted).

Tab. ab. 28

SIG IGMA MA CONT CONTR ROL ke keys  ys 

Fig ig.. 7

SIG IGMA MA CONT CONTR ROL in indi dicat cator ors  s 

Symbol

Ite Item Description

Function

12

Display

Alp h ha anumeric d is isp lla ay with 4 lines.

13

Alarm

Blinks red when an alarm oc c urs. Lights continuously when acknowledged.

14

Commun Communica icati tion on

Li Light ghts s red red if comm commun unica icatio tion n via via the Prof rofibu ibus s is in inte terrrupted.

15

Service rvice/w /wa arnin rning g LED

16

Cont Contro roll lle er powe power ON

Blinks yellow for: --- maintenance work required --- warning message Lights Ligh ts green when the power supply to the controller is switched on.

17

LOAD

Lig ht hts green when the mac h hiine is in the o p pe erating state LOAD

18

Ope Operati rating ng mode mode IDLE 

Lights green when the machine is in the IDLE mode.

19 Tab. ab. 29

Machi chine ON

Blinks green if the manualLOAD / IDLING IDLING changeover key (5) is used. The ma mach chiine is swi witc tch hed on. on.

SIG IGMA MA CONT CONTR ROL indica indicator tors  s 

4 --- 21

 

Installation and Operating Conditions 5

Inst Instal alla lattio ion n and and Oper Operat atin ing g Co Con ndit ditio ion ns

5.1 5. 1

Ambien bientt Co Con nditi dition ons s  

 

 

 

 

 

 

There must be no open flames or sparks at the place of installation. Any welding welding work c arried arried out on the equipment equipment must not cause a fire hazard hazard through flying sparks or excessive temperature. The machine is not explosion---proof. Do not operate in areas in which specific requirements with regard to explosion protection are applied. applied. For instance, the requirements of 94/9/EU (ATE (ATEX X directive) for co rrect use in explosion hazardous areas. areas. Clean inlet air with no damaging contaminants. Inlet air free of explosive or chemically unstable gas or vapour. Ambient temperature must be acceptable and stable. The airend discharge temperature must remain constant to prevent the build---up of condensate.

 

Suitable fire extinguishing material must be to hand.

5.2

Inst Instal alla lati tion on Co Cond ndit itio ions ns

5.2.1 5.2 .1

Place Place of inst install allat ation ion an and d sp space ace requi required red  

 

The floor must be level, firm and able to bear the weight of the equipment. If installed installed outdoors, the equipment equipment must be protected from frost, direct sunlight, sunlight, dust and rain.

5 --- 22

 

Installation and Operating Conditions

Fig. 8 A B Z

5.2. 5.2.2 2

In Inst stal alla lati tion on recomm recommen enda dati tion, on, dimen dimensi sions ons [mm] 

Exha haust ust fa fan  n  Exha haust ust ai airr duct  In Inle lett ai airr openi opening  ng 

Venti entila lattion ion Values given are minimum guidelines. If the inlet aperture is insufficient a dangerous vacuum can be created in the compressor room. Ensure that the volume of air flowing into the compressor room is at Ensure least equivalent to that being removed from it by the compressor and exhaust fan.

 

Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually open.

 

Inlet opening [m   ] (op tio n K1) Extractor for forced ventilating: Flow rate [m  /h] at 100 Pa (option K1) Inlet opening [m   ] (op tio n K2)  

C SD 82 1 16000

C SD 102 1,3 22000

C SD 122 1,6 25000

0,3

0,3

0,3

 

 

5 --- 23

 

Installation and Operating Conditions

Extractor for forced ventilating: Flow rate [m  /h] at 100 Pa (option K2) Exhaust air duct:

CSD 82 3000

CSD 102 3000

CSD 122 3000

700 x 700

700 x 700

700 x 700

 

Dimensions Dime nsions [ mm] Tab. 30 Ven enti tila lati tion  on 

Exhaust ducting Consultt the manufacture Consul manufacturerr on the design design of the ducting, length, number of bends, etc. Further information on exhaust air ducts can be found in chapter 13.2.3. Air---cooled compressors (option K1) have two exhaust apertures, a large one for the o il cooler and a smaller smaller one for the rest of the machine. If a single exhaus exhaustt d uct is to be connected to both exhaust exhaust apertures an auxiliary fan (option K4) must be installed. If the machine is ordered with option K4, the auxiliary fan is already installed.  

5.2.3 5.2 .3

If necessary, the auxiliary fan must be installed by an authorised KAESE KA ESER R technician.

Operat Operatin ing g in a com compre press ssed ed air netw network ork When the machine is connected to an air network, the network operating pressure must not exceed 16 bar. Initial filling of a fully vented air network generally creates very a high rate of flow through air treatment devices. These conditions are detrimental to correct air treatment. Air quality suffers. To ensure maintenance of desired air quality when filling a vented air main we recommend the installation of an air main charging system. KAES KA ESER ER is ready to offer offer go od advice. advice.

5 --- 24

 

Installation 6

I nstallation

6 .1

Safety There is considerable danger of injury or death if insufficiently or inadequately treated compressed air is used. DANGER Injury and/or poisoning c aused Injury aused by the use of insufficie insufficiently ntly treate treated d compressed air as breathing air or for the processing of foodstuffs.  

 

WARNING

Never use compressed air as breathing air unless it has been suitably treated, the pressure is appropriately reduced and breathing apparatus is used. Use foodstuff---compatible cooling oil and suitable treatment whenever compressed air is to come into contact with foodstuffs.

There is considerable danger of injury or death because of spring forces when spring spring --- loaded components are incorrectly incorrectly opened (dismantled). Minimum pressure/check valves, pressure relief valves and inlet valves are heavily spring loaded.  

Do not open (dismantle) valves.

All functioning parts are factory set. Changes may not be made without the permission of the manufacturer. Installation Installa tion may only be carried out by persons fully fully c onversan onversantt with the basic safety safety c oncepts of compressed air engineering.

6.2

Re Repo port rt an any y Tra rans nspo port rt Dam Damage age Check the machine for visible and hidden transport damage.

 

Inform the carrier and the manufacturer in writing of any damage.

 

6.3

Ins Instal talll th the e Com Compre press ssed ed Ai Airr Con Connec necti tion on Pre --- condition: condit ion:   air main main completely vented. vented.

Fig ig.. 9 1 2

Compr ompres esse sed d Air Conn Connect ectio ion  n 

Ax Axial ial compensator or flexible flexible hose  Shut-hut---off valve  valve 

6 --- 25

 

Installation  

 

6.4 6. 4

Shut---off valve (2) to be installed by the user in the connection line. Make the compressed air connection with a flexible hose (1) or an axial compensator (1).

Elect lectri rica call Co Con nnec ecti tion on 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 VD E 0100, for example) and in national a acc ccident ident prevention regulations (BGV A2 in Germany). Also observe the regulations of the local power utility company. Use wire conductor dimensions dimensions and fuse ratings in accordance with local regulations regulations (DIN VDE 0100 parts 430 and 523 in Germany, for example). Check the reaction time of overload protection devices (e.g. DIN VDE 0100 part 413). Guide values are given in chapter 2.8.  

The user must provide the machine with a lockable supply---disconnecting device. This could be, for example, a switch---disconnector with fuses. If a circuit breaker is used use d it must be suitable for the motor starting starting characteristi characteristics. cs.

Before initial start---up  

The The control transformer transformer in the control cabinet cabinet has c onnections for various supply voltages.. Check that the c orrect c onnections are made ages made for the supply voltage provided provided for the machine. If necessary, re---connect the transformer using the   5% taps to match the supply voltage.  

 

Connect the machine to the mains power supply in accordance with the ele Connect electrical ctrical diagram in chapter 13.2.4.

6 .5

Options

6.5.1 6.5 .1

Machine Machine fix fixing ing (optio (option n H1) If the machine is supplied supplied with mountings, mountings, these can be used to anchor it to the floor. floor. Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.3.  

6.5.2 6.5 .2

Use appropriate appropriate bolts to anchor the machine.

Water ater cooli cooling ng con conne nect ction ion (opt (option ion K2) The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the cooling water connection ports. Use connecting lines made of the appropriate material for the water system. Take into account the effect of electro---chemical reaction. Keep the effect of pressure surge on the cooler as low as possible. Where pressure surges are unavoidable provide an expansion tank to damp pulsations.

6 --- 26

 

Installation

Fig ig.. 10 A B

Wate terr coolin cooling g conne connecti ction  on 

Co oling water outlet Co oling water inlet

10 12 17

Shut --- o ff valve   Co nnec tio n p ort with sto pp er   Pr Pressur essure e relief relief va valve  lve 

The user is to provide the following fittings:  

 

 

Dirt trap with max. 0.1 mm strainer mesh. Shut---off valves (10) and connection ports (12) for maintenance and venting. Pressure relief relief valve (17) prevents build ---up of excessive pressure. Blowoff pressure and capacity are related to the user’s installation design. Keep to the cooler technical specification.

 

 

 

 

Connect Conne ct the cooling water line to the fitting. fitting. Open the shut---off valve on the cooling water outlet (A). Slowly open the cooling water inlet shut---off valve (B) to gradually fill the cooler with water. Vent tthe he water lines.

6.5.3 6.5 .3

Heat Heat recov recovery ery sy syst stem em conne connecti ction on

6.5.3.1

Internal Internal heat recov recovery ery (opti (option on W2, W W3) 3) The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the connection ports. Use connecting lines of suitable material. Take Take into ac account count the effect of electro ---c hemical reaction. Keep the effect of pressure surge on the heat exchanger as low as possible. Where pressure surges are unavoidable provide an expansion tank as a damper.

6 --- 27

 

Installation

Fig. 11 A B

Hea eatt recov ecover ery  y 

Outlet Inlet

10 12 17

Shut --- o ff valve   Co nnec tio n p ort with sto pp er   Pr Pressur essure e relief relief va valve  lve 

The user is to provide the following fittings:  

 

 

Dirt trap with max. 0.1 mm strainer mesh. Shut---off valves (10) and connection ports (12) for maintenance and venting. Pressure relief relief valve (17) on o n the inlet (B) prevents build ---up of excessive pressure. Blowoff pressure and capacity are related to the user’s installation design. Keep to the heat exchanger technical specification.

 

 

 

 

6.5.3.2

Connect the water lines to the fittings. Open the shut---off valve on the outlet (A). Slowly open the inlet (B) shut---off tap to gradually fill the heat exchanger with water. Vent the lines.

Extern External al heat heat recovery recovery s sys ystem tem (option (option W1) W1) The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the connection ports.  

Follow the manufacturer’s instructions on connecting the external heat exchanger.

6 --- 28

 

Initial StartStart --- up 7

Init Initiial Star artt----up

7.1

Bef Before ore Init Initial ial StartStart----up (or Recom Recommis missio sionin ning) g) A trained specialist may only carry out the initial start---up procedure. Incorrect start---up can cause damage to the machine.

Special measures on recommiss recommissionin ioning g after storage Storage period longer than   12 months

Action  

 

 

 

36 months

7.2

 

 

Change the oil filter. filter. Change the oil separator cartridge. Change Cha nge the c ooling oil. Have the motor bearings bearings c hecked by an authorised authorised KAESER KAE SER service agent. Have the overall overall technica technicall condition checked by an authoauthorised KAESER KAESER service agent.

Ch Check eck Ins Instal tallat lation ion and Oper Operati ating ng Con Condi diti tion ons s Cover all points in the check list before starting the machine.

C heck 1   All installatio n c ond itio ns fulfilled? User’s r’s lo locka ckabl ble e su suppl pply y di disc scon onne necti cting ng de devi vice ce in inst sta alle lled? 2   Use 3   Is th the e powe powerr suppl pply as speci peciffied on the the namepl mepla ate te? ? 4   Suppl pply cabl cable e sect ctiion and fuse rati tin ng ade dequ qua ate te? ? connec tions checked for tightness? 5   All electrical connections 6   Shut-t---o -offf valve fitted to c o om mp re ressed air o u uttlet? Connection ction made made to air air main with hose or axia axiall compen7   Conne sator? 8   Suffi Sufficient cient coo ling oil in the oil separator tank? (cooling oil indicator outside the red zone?) zone?) equi uire red d quanti quantity ty of coolin cooling g oil pou poure red d in into to the inle inlett port port? ? 9   Req 10   Motor protection rel relay ay set correctly with regard regard to the power supply? 11   Operators full conversant with safety regulations? 12   Supply of coo ling water ensured? (option K2) 13   Machi Machine ne anchored anchored to the floor? (option H1) 14   All access doors closed and latched and all removable panels in place and secured? Tab. 31 Checkli Checklist, st, ins insta talla llati tion on conditions  conditions   

 

 

 

C hapter 5 6. 6.4 4 2 2.8.2

Done?

 

 

 

6.3 6.3

 

 

 

7. 7.5 5 7.4

 

 

 

 

7.3

6.5.2 6.5.1 4.1.1

Set Setti ting ng the the ov overl erload oad pro protec tecti tion on cu cutt ---out Compressor motor In the star---delta configuration the phase current is fed via the overload protection cut--out. This phase current is 0.58 times the rated motor current (see motor nameplate).

7 --- 29

 

Initial StartStart --- up Setting The standard setting is made at the factory. To prevent the overload protection cutout from being triggered by voltage fluctuations, temperature influences or component tolerances, the setting can be up to 15% higher than the arithmetical phase current.

7.4

Mot Motor or Pr Prot otec ecti tion on Sw Swit itch ch Set Setti tin ng Fan motor In direct on---line start the starting current is fed via the motor overload protection switch. Setting The standard setting is made at the factory. To prevent the overload protection switch from being triggered by voltage fluctuations, temperature influences or component tolerances, the setting can be higher than the motor rated current (see motor nameplate).

7.5

Po Pour ur Co Cool olin ing g Oil Oil into into the the In Inle lett Po Port rt The airend must be manually filled with cooling oil before initial start---up and after being out of use for more than 3 months. Use the same same type of oil. A sticker giving the type of oil used used is found near the oil separator separator tank filling port.

Fig. 12  1 2  

















































 

Screw cre pl plug  In Inle lett w val alv vug  e  Remove the plug (1) from the inlet valve (2).

Pourr c ooling oil into the airend. Pou airend.

 

Fig. 13  1 2















 

 

 

Co mpressor b lo c k Co upling

3 4

Co ver   Rotational d irec tio n arro w  

7

30

 

Initial StartStart --- up  

 

 

 

7.6

Remove the cover (3). Note the rotational direction arrow (4). Grasp the coupling (2) and turn it and the airend shaft (1). Repla eplace ce the coupling c over (3).

Ch Chec ecki king ng Di Direc recti tion on of Ro Rota tati tion on The machine is designed for a clockwise field.  

 

Check the supply with a phase sequence indicator. If the compressor 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.  

7.7 7. 7

Switch the machine off as soon as the direction of rotation is see Switch seen n and compare it with the direction arrows on the motor and airend.

In Init itiial Star Startt----up  

 

Open the shut---off valve to the air network. Switch on at the main supply isolator.

The controller makes a self---test and the green LED ’Power ON’ (16) lights.  

 

Press the ’Operating state LOAD/IDLE’ key. Press Pre ss the ’ON’ key (2).

The green LED ’Machine ON’ lights (1).  

Allow the machine to idle for at least one minute.

This This ensure ensures s go od distribution distribution o f c ooling oil.  

Press the ’Operating state LOAD/IDLE’ key.

The machine switches to the LOAD state and delivers compressed air. Watch for any faults faults occ urring in the first hour o f operation. After After the first 50 operating operating hours carry out the following: following:  

7.8

Check that all electrical connections are tight.

Set Setti ting ng Net Netwo work rk Pr Pres essu sure re The network pressure (working pressure) is set at the works. Adjustment is possible to suit individual operating conditions.  

Network pressure setting is described in the SIGMA CONTROL service manual. The machine may toggle a maximum of twice per minute between LOAD and IDLE. Reducing starting frequency:  

 

Increase the difference between cut---in and cut---out pressure. Add an air receiver downstream to increase buffer capacity.

7

31

 

Operation 8

Operation

Fig ig.. 14 1 2 3 4

8.1 8. 1

Swi witch tchin ing g On and Off 

’Mac hine ON’ LED (green) ’ON’ key (’I’) OFF key (’0’) ’Clo c k’ key

5 6 7 8 13

’ Remo te’ key   ’ LOAD   ’ LED  ’ IDLE’LED   ’ Po wer ON’ LED (g reen) LOAD OAD / ID IDLEtogg LEtoggle le key  key 

Sw Swiitching On an and d Of Offf

Always Alw ays switch the machine on and off with the ’ON’ and ’OFF’ ’OFF’ k eys. The supply disconnecting device is installed by the user.

8.1. 8.1.1 1

Swit Switch chin ing g on Compressed air can cause serious injury! WARNING

Serious injury possible.  

 

Never direct compressed air at a person or animal! Ensure that:  

 

 

 

 

no one is working on the machine, all panels are in place, all access doors are closed, no parts of the machine are are colder than + 3 ˚ C.

Switch on at the main supply isolator.

The controller makes a self---test and the green LED ’Power ON’ (16) lights.  

Press Pre ss the ’ON’ key (2).

The green LED ’Machine ON’ lights (1). The compressor motor runs, assuming the network pressure is lower than the cut---out pressure.

8.1.2 8.1.2

Autom utomat atic ic rest restar artt Pre --- condition: condit ion:   Network pressure is lower than cut ---o -out ut pressure. Automatic restart is factory---set. The machine restarts automatically when power is resumed after a power cut.

8

32

 

Operation 8.1. 8.1.3 3

Swit Switch chin ing g off off Press the ’LOAD/IDLE’ toggle key (13).

 

The machine switches to IDLE and the LED (7)  blinks. After running in idle for 20 seconds, press the OFF key (3).

 

The ’Machine ON’ LED goes out (1). Switch Swi tch off and lock out the main supply isolator isolator..

 

8.2

Sw Swit itch chin ing gO Off ff in an Em Emerg ergen ency cy and Sw Swit itch chin ing gO On n Agai gain n

Fig. 15 9

Swi witchi tching ng off in an emer emergen gency  cy 

EMER MERGENC GENCY Y STOP but button  ton 

Switching off  

Press the ’EMERG ’EMERGENCY ENCY ST STOP’ OP’ butto n (9)

The ’EMERG ’EMERGENCY ENCY ST STOP’ OP’ remains latched latc hed in. The machine pressure system is vented and the machine is prevented from re---starting.

Starting Startin g again Pre --- condition: condit ion:   Fa Fault ult rectified. rectified.  

 

 

8.3

Turn the ’EMER ’EMERGENCY GENCY ST STOP’ OP’ button in the direction of o f the arrow to unlatch it. Press the ’Reset’ key (11). Switch Swi tch the machine on.

Re Remo mote te On an and d Of Offf Sw Swit itch chin ing g Pre --- condition: condit ion:   Connection Connection to a remote control device. device.  

Press the ’Remote’ key (5).

The The LED in the corner of the key lights. The The remote control device device has c ontrol of the machine. The machine can still be switched on and off by the ’ON’ and ’OFF’ keys (2 and 3) if required.

8

33

 

Operation Apply the remote warning label to the machine where it is plainly visible. BEWARE! This machine is remotely controlled and can start at any time. La Label bel the remote c ontrol device accordingly:

”Before starting, make sure that no one is working on the machine and it can be safely started.”

8.4

Sw Swit itch chin ing g on an and d off off wi with th the the Cl Cloc ock k Pre --- condition: condit ion:   Clock programmed programmed Press Pre ss the ’Clock’ key (4).

 

The The LED in the corner of the key lights. The The integrated integrated cloc k has c ontrol of the machine. machine. Apply the time---controlled warning label to the machine where it is plainly visible. ”BEWARE! This machine is clock---controlled and can start at any time.”

8.5

Ac Ackn know owled ledgi ging ng and Res Resett ettin ing g Wa Warn rnin ing g an and d Alarm Alarm Mess Messages ages

Fig. 16 10 11 12

Acknowledging and Re Resett setting ing War arning ning and Alar larm m Messages  Messages  ’War ’Warnin ning’ g’ LE LED D (yell (yellow) ow) ’A ’Ala larm rm’’ LED LED (red) (red) ’A ’Ackno cknowl wledg edge’ e’ (res (reset et)) ke key  y 

Alarm An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11).

Warning The display shows a maintenance or warning message. The yellow warning LED (10) blinks, for example, if a maintenance task is due.

8.5.1 8.5 .1

Reset Resetti ting ng ala alarm rm messa messages ges Pre --- condition: condit ion:   Fa Fault ult rectified. rectified.

8 --- 34

 

Operation  

Press the ’Acknowledgement (reset)’ key (12).

The alarm LED (red) goes out (11). The machine is now ready to start again.

8.5.2 8.5 .2

Reset Resetti ting ng wa warn rnin ing g mes messa sages ges Pre --- condition: condit ion:   The cause of the warning elimina eliminated. ted. Maintenance task completed.  

Press the ’Acknowledgement (reset)’ key (12).

The warning LED (yellow) goes out (10).

8 --- 35

 

Event Recognition and Fault Rectification 9

Even Eventt Reco Recogn gnit itio ion n an and d Fault ault Re Rect ctif ific icat atio ion n Inform KAES KAESER ER service service if the event event c annot be rectified by the action suggested. Do not attempt rectifications other than those given in this manual. The measures valid for your machine are dependant on the individual equipment. There are three types of event:

Description An event that triggers an alarm (with automatic shut---down) An event that triggers a warning (no shut--down) Misc ellaneo us events (faults)

9.1

I ndicated by Blink ing red LED

see chapter 9.1

Blink ing y ello w LED

9.2

No ind ic atio n

9.3

Alarms Alarms (mach (machin ine e shu shutt --- dow down, n, red LE LED D bli blinki nking) ng) M essage

Possible cause

Action

ac c ce ess d o oo o rrs s

Doo r op en ened d ur uring machine operation. Maximum airend discharge temperature exceeded.

Close the door(s).

ADT

 

 

KAESER service technician only

Ensure adequate ventilation. Ensure permitted room temperature not exceeded. Clean the cooler. Cooling air outlet too near a wall

ADT d T/d t

air ire end ro rota tati tion on

AI 1 o p pe en c c ctt.

AI 2 o p pe en c c ctt.

Maximum airend d ischarge temperature rise rate exceeded. The moto motorr is turn turniing in the wrong direction. Connec titio n is bro ken between the system pressure transducer and analog input 1. Short circuit to earth. Connec titio n is bro ken between the internal pressure transducer and analog input 2. Short circuit to earth.

Check the cooling Check oil level level.. Check airend and piping to airend. airend. Check Che ck the cooling oil level level.. Check oil c ircula Check irculation. tion. Changeover phase lines L1 and L2. Check line and connection.

Check the sensor.

Check line and connection.

Check the sensor.

9 --- 36

 

Event Recognition and Fault Rectification M essage

Possible cause

Action

AI 3 o p pe en c c ctt.

No c on onnec titio n b eetween the sensor measuring airend di-

Check line and connection.

AI 4 o p pe en c c ctt.

AI 5 ope open cct cct.

AI 6 ope open cct cct.

scharge ture and temperathe analog input 3. No c on onnec titio n b eetween the sensor measuring motor temperature and the analog input 4. There is no con connection between the sensor allocated to analog input 5 and the input itself. Short circuit to earth. There is no con connection between the sensor allocated to an analog input and the input itself.

KAESER service technician only Check the sensor.

Check line and connection.

Check the sensor.

Check line and connection.

Check the sensor.

Check line and con-

Check the sensor.

nection.

Short circuit to earth. ... AI 8 open cct. AI 1 shor ortt cct cct.

... AI 8 short cct. back back pre press ssur ure e

b lo lo wo wo ffff p rro o t. t.

The con connecti ction bebetween the sensor and the analog input is shorted.

Check line and connection.

Replace Replace defective sensor.

Back pre pressure ure in the the oil separator tank caused by poor venting.

Ch Check eck ve venti nting ng line line..

Ch Check eck ve venti nting ng valve valve..

The blowo ffff pressure of the pressure relief valve on the oil separator tank has been exceeded.

Change the oil separator c artridge. artridge.

Chec k minimum pressure/check valve.

Open the shut ---o -off ff valve in the venting line.

Check the minimum pressure/check valve, the control valve and the inlet valve. Check sensor, line and co nnection. nnection.

conden cond ensa sate te drain drain cooli coo ling ngwa wate terr lo low w

Fault ault in conden condensa sate te drainage. Cool Coolin ing g wate waterr pre pressure too low.

Check condensate drainage. Check Che ck cooling water supply. Check that cooling Check water shut---off valve is fully open.

9 --- 37

 

Event Recognition and Fault Rectification M essage

Possible cause

Action

EMERG EME RGENCY ENCYST STOP OP

EMERG EMERGENCY ENCY ST STOP OP button pressed.

Unlatch the pushUnlatch button. Rec tify fault.

First fan motor shut down because of overload. Second Second fan motor shut down because because of overload. Third fan motor shut down because of overload. Fault in the hig h ten sion cell. The main mains s conta contacto ctorr does not drop out

Investigate cause.

ext. messag e 0 ... ext. message 5   Fan M2 I  

Fan M3 I

 

 

Fan M4 I

 

 

HT c el ell main ma ins s con cont. t. off? off?

Reset overload trip. Investigate cause. Reset overload trip. Investigate cause. Reset overload trip. Check high tension cell. Check auxiliary contact block.

despite an OFF command. main ma ins s con cont. t. on on? ?

maiins moni ma monito torr mod el

Check Che ck 230 V avaiavailable for the contaclable tor. Check auxiliary contact block on K1M.

The main mains s conta contacto ctorr does not pull in despite an ON command. Fault ult in mai mains powe powerr supply. Mac hine mod el indistinct

KAESER service technician only

Check 230 V avaiCheck available labl e for the contactor. Have the mains power supply checked. Re---enter Re--ent er model mod el name Exchange controller

motor I

motor T

 

 

 

 

Drive Drive motor shutdown because of overload.

Drive Drive motor overheated.

Change the oil separator c artridge. artridge. Check minimum pressure/check valve. Investigate cause. Ensure adequate ventilation. Install an extractor.

moto mo torr bea bearing rings s

neutral p --- switc h neutral T --- switc h

Driv rive moto motorr bea bearings overheated.

Clean the motor. Grease the motor bearings bear ings with the greasing device. Rec tify fault Rec tify fault

Change motor bearings.

9 --- 38

 

Event Recognition and Fault Rectification M essage

Possible cause

no press press.. bui buildu ldup p

Machi Machine ne produce produces s no compressed air. The setpoint pressure does not rise above 3.5 bar for a preset period.

O 0.6/A 0.7

Sho rt c iirrc u uiit in the line between output O 0.6 or O 0.7 and a consumer. Sho rt c iirrc u uiit in the line between output O 1.6 or O 1.7 and a consumer. No changeover changeover to load as long as the minimum minimu m o il pressure is not reached.

O 1.6/A 1.7

oil p

 

 

 

PD temperature

 

 

PD temperature

 

Power supply

pRV

 

RD compr. p

 

 

 

KAESER service technician only Check for air leaks. Check the inlet Check the coupling /  valve. Check minimum V---belts. pressure/check valve.

Check line and connection.

Compare the ’internal pressure’ indicated with the reading shown on the oil separator tank pressure gauge. Check the consumer.

Check line and connection.

Check the consumer.

Check Che ck oil c ircula irculation. tion. Replace Replace defective switch. Check pressure switch, line and and connection.

Compressor outlet temperature too low.

Compressor outlet temperature too high. 2. Power ower fa fail ilur ure e

 

 

Action

The blowoff pressure of the pressure relief valve on the oil separator tank has been exceeded. Pressure Pressure switch on the refrigerant compressor activated.

Check sensor, regulator.

Check the fan motor. Clean the cooler. Check the cooling Check oil level level.. Chec Check k powe power su suppl pply y voltage.

Check the frequency converter. Check sensor, regulator. Check the frequency converter.

Check lock. door interReplace the pressure relief valve.

Ensure adequate ventilation. Clean the refrigerant Clean condenser. Clean the cooler.

Replace Replace defective sensor.

9 --- 39

 

Event Recognition and Fault Rectification M essage RD compr. T

 

 

Possible cause

Action

Refrigerant Refrigerant comp ressor overheating.

Clean Clea n the refrigerant condenser.

KAESER service technician only

Ensure adequate ventilation. Install an extractor. Cleaning the cooler RD compr. T

 

Refrigerant Refrigerant comp ressor too cold.   Oil separator cartseparator dp ridge clogged.   Maximum temperaseparator T ture on oil separator tank outlet exceeded. SIGMA CONTROL T   SIGMA SIGMA controller contr oller housing temperature exceeded 70˚ C.  

 

 

 

Check refrigeration dryer. Replace the oil separator cartridge. Check the cutout line.

Check the cutout on the oil separator tank outlet.

Ensure adequate ventilation. Ensure permitted room temperature not exceeded. Check control cabinet ventilator (filter mats).

softstart start T

 

 

Fault in the so ft start system. Air temperature at the airend discharge port too low.

Ambient temperature below + 3˚ C. VV----belts -belts broken broken The VV----belts -belts pa parte rted d during machine operation. VFD Freq uenc y c o nverter faulty. Tab. ab. 32 Alarm larm mess messag ages es and and act action ions  s 

Heat the compresHeat sor room.

Check the soft start system. Install auxiliary heating.

Replace Replace the V---belts. Check the frequency converter.

9 --- 40

 

Event Recognition and Fault Rectification 9.2

Wa Warn rnin ing g Mess Messages ages (yel (yello low w LED blin blinki king ng)) M essage

Possible cause

Action

ac c ce ess d o oo o rrs s

Doo rs rs o p pe ened dur-

Close access doors.

ADT

ing tion.machine operaThe maximum permissible airend discharge temperature will soon be reached.

 

 

KAESER service technician only

Ensure adequate ventilation. Clean the cooler. Cooling air outlet too near a wall. Check Che ck the cooling oil level level..

air filter dp

 

 

The pressure drop across the air filter is rising.

Replace Replace the oil o il filter. Clean/replace Clea n/replace the t he air filter element.

Air filter element element clogged. air filter h

 

 

Bearing maintenance h

 

b lo wo ff p ro t.

Buff Buffe er ba batt tte ery b us alarm

conden cond ensa sate tedra drain in elect. equip. h

 

ex ext. t.loa load d si signa gnal? l?

 

The service interval to the next air filter element check has expired. The service interval to the next bearing greasing has expired. Warning The blowoff pressure of the pressure relief valve will soon be reached.

Da Datata----re -rete tent ntio ion n ba batttery run down. The bus link fro m the Profibus DP interface is interrupted. Fault ault in conden condensa sate te drainage. The service interval for checking electrielectrical equipment and wiring has expired. Extern xternal al loa load d si signa gnall indistinct: Increased cut ---out -o ut pressure exceeded. The external load control has not switched switche d to idle.

Clean/replace Clea n/replace the t he air filter element.

Grease the motor bearings.

Change the oil separator c artridge. artridge. Open the shut ---o -off ff valve in the venting line.

Check Che ck link link and plug.

Check the minimum pressure/check valve, the control valve and the inlet valve. Check the pressure transducer. Contact KAESE KA ESER R service. Check Check the interface interface configuration.

Check condensate drain and lines. Reset the service interval c ounter. ounter.

Check electrical components.

Check settings Check settings of the external controller.

Check discrepancies between pressure transducers.

Take the pressure drops across filte and dryer intofilters ac-rs count.

9 --- 41

 

Event Recognition and Fault Rectification M essage

Possible cause

Action

err rror or:: RS 485

Wron rong con configura gurati tion on or transmission error.

Check the link/interface co nnections nnections between the two

Bit rate and c haracharacter frame for both subscribers identical.

controllers. Check maximum cable length and screening.

KAESER service technician only

Check interface parameters. 1 master and 1 slave configured. Rec tify fault.

ext. messag e 0 ... ext. message 5 flash memor mory mains voltage

Inte terrnal con control trolller memory error. 1. power failure: failure: Machine was re--started automatically.

 

 

mode mo dem m pr probl oble em

SIG IGMA MA CONT CONTR ROL does not recognise the modem.

motor T

Drive Drive motor overheating.

 

 

Exchange Exchange the cont cont-roller. Check power supply Check voltage. Check door interlock. Check Che ck the link between the SIGMA controller and the modem. Ensure adequate ventilation. Install an extractor. Clean the motor.

motor bearings bearings h

motorstarts /h

 

motor starts /d

 

 

 

 

 

The service interval to the next motor bearing change has expired. The permissible number of motor starts was exceeded in the last 60 minutes.

The permissible number of motor starts was exceeded in the last 24 hours.

Change motor bearings.

Extend the idle period. Increase capacity of air receiver.

Increase cross ---sec tion of piping between compressor and air receiver. Extend the idle peCheck pressure riod. transducer. Increase capacity of air receiver. Increase cross ---sec tion of piping between compressor and air receiver.

neutral p --- switc h neutral T --- switc h

Check pressure transducer. Replace Replace defective sensor.

Rec tify fault Rec tify fault

Replace Replace defective sensor.

9 --- 42

 

Event Recognition and Fault Rectification M essage

Possible cause

Action

no pr pre ess ss.. bu buil ildu dup p

The compr compre ess ssor or cannot build ---up pressure.

Check for air leaks.

oil change h

oil filter dp oil filter h

oillevel oil T

 

 

The service interval to the next oil change has expired. Oil Oil fi filte lterr clogge clogged. d. The service interval to the next oil filter check has expired. Oi Oill le leve vell too lo low w.

 

 

 

 

 

 

 

 

Cooling oil temperature too low low..

Check the value given in the analog data menu with the reading rea ding on the oil separator tank pressure gauge. Change the cooling oil.

 

 

 

PD temperature

Top up th the e coolin cooling g oil. Increase room temperature.

RAM

Remaining oil content  

Remaining Remaining oil content

separator dp

 

 

 

Warning Compressor Compres sor d ischarge temperature too high. Internal RAM defec tive. Warning The purest class oil content limit will soon be reached. reached.

Check venting valve.

Replace Replace defective switch. Install auxiliary heating.

Check sensor, regulator.

Warning Compressor outlet temperature is low.

 

valve and the inlet valve.

Chan Change ge the oil filt filter er.. Change the oil filter.

Check the oil circuit. Check temperature gauge switch, line and connection. PD temperature

KAESER service technician only Check the minimum pressure/check valve, the control

Clean the cooler.

Check the frequency converter. Check the fan motor.

Check the cooling Check oil level level.. Check controller. Exchange Exchange the cont cont-roller. Check the scavenge tube in the oil sepaseparator tank.

The purest class oil content limit is exceeded.

Check the dirt trap Check strainer in the scavenge line. Check the scavenge tube in the oil sepaseparator tank.

Oil separator cartridge clogged.

Check the dirt trap Check strainer in the scavenge line. Change the oil separator c artridge. artridge.

Check the oil sepaCheck rator c artridge. artridge. Check oil sensor line and co nnection. nnection.

Check the oil sepaCheck rator c artridge. artridge. Check oil sensor line and co nnection. nnection.

9 --- 43

 

Event Recognition and Fault Rectification M essage separator h

Possible cause  

 

 

 

has expired. The ’set o utput’ test function is activated. System pressure has fallen below the set ’low’ value. Air consumption too high.

System pressure

 

(vacuum machines only)

VFD mains

VV----belt -belt tens tension ion V---belt tens. h

Tab. 33

9.3

 

KAESER service technician only

The service interval Change the oil sepato the nex nextt o il sepa- rator c artridge. artridge. rator cartridge check

set o utput System pressure

Action

 

System pressure has fallen below the set ’high’ value.

Failure o f po wer supply to the frequency converter. VV----belt -belt tens tension ion too low. The service interval to the next V---belt re---tensioning has expired.

End the ”set output” mode. Check air demand. Check line and connection. Check ’systpress. low’ setting. Check for air leaks.

Check pressure transducer. Replace Replace defective sensor.

Check ’syspress. high’ setting. Check if the machine switches to LOAD. Check Che ck power supply. Re---tension the V---belts. Re---tension the V---belts.

War arnin ning g messa messages ges an and d actions  actions 

Mis Misce cell llan aneou eous s ev even ents ts (fa (faul ults ts)) Alarm

Possible cause

Action

Motor overload protection relay tripped out.

Overload relay is defective fectiv e or incorrectly set. Oil separator cartridge clogged.

Check setti tting ng..

KAESER service technician only Repla place th the e ov ove erload relay.

Check pressure drop across the separator cartridge. Change the oil separator cartridge if necessary.

The press pressur ure e sys sys-does not vent. vent. tem   does

Motor defective; bearing damage or windings shorted. Airend defec tive.

Open Open th the e sh shutut----off valv valve e in the venti venting ng line.

Check Check venti venting ng va valv lve. e. Check minimum pressure/check valve. Check the motor.

Chec k the airend .

9 --- 44

 

Event Recognition and Fault Rectification Alarm

Possible cause

Machine runs but produces produce s no compressed air.

Inlet valve not opening or only opening partially.

Action

Venting valve not closing. Pressure system lea- Check Check pipework and king. connections for leaks and tighten. The air demand is Check air network greater than the cafor leaks. pacity of the compShut down the conressor. sumer(s). Hose coupling or maintenance hose still plugged into the quick---release coupling on the oil separator tank.

Remove coupling or maintenance maintenan ce hose.

Cooling runs out of the airoil filter.

Oil level intoo thehigh. separator tank

Drain offlevel oileluntil the correct lev is reached.

Compressor switcCompressor hes between load and idle more than twice per minute. minute.

Inlet valve d efec tive Air receiver too small. Flow into the air network restricted. restricted.

KAESER service technician only Check the valve.

Check venting valve.

Install auxiliary compressor.

Chec k the valve. Install an air receiver of sufficient capacity. Increase air line diameters. Check filter elements.

Oil leaking into the floor pan.

Cooling oil consumption too high.

Hose coupling or maintenance hose still plugged into the quick---release coupling on the oil separator tank. Oil c o oler leaking

Remove coupling or maintenance maintenan ce hose.

Conne Con nection ction leaki leaking. ng.

Tighten ighten connecconnections.

Unsuitabl Unsu itable e oil used. used. Oil separator cartridge split. Oil level in the separator tank too high. Oil return line clogged.

Tab. 34

Mis Miscella cellaneou neous s event events s (fa (fault ults) s)

Rep lac e the oil c o o ler.

Replace seals. Use SIGMA SIGMA FLUID FLUID cooling oil. Change the oil separator c artridge. artridge. Drain off oil until the correct level level is reached. Check dirt trap in the oil return line.

9 --- 45

 

Maintenance 10

Mai Maintenance

1 0 .1

Safety Disregarding these notes and/or improper handling may result in serious injury. Electric shock can kill! DANGER

Touching electrically live components can cause serious injury or death.  

 

 

 

 

 

Isolate Isola te comp letely letely from the mains supply (all conduc tors) (switch off at the main isolator) Ensure Ens ure the supply cannot b e switched on again again (lock off). Check that no voltage is present. Only work on electrical components when they are voltage---free. Work carefully. Before switching on again ensure that:  

 

 

WARNING

no one is working on the machine, all panels are in place and secured, all access doors are closed.

There is considerable danger of injury or death from the release of spring sprin g force if sprin spring g --- loaded components are incorrectly incorrectly opened (dis( dismantled). Minimum pressure/check valves, pressure relief valves and inlet valves are under powerful spring loading.  

Do not open (dismantle) valves.

Compressed air can cause injury or death. WARNING

Serious Serious injury or d ea eath th c an result result from loosen loosening ing 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. De---pressurize all pressurized components and enclosures. Check all machine hose connectors with a hand---held pressure gauge to ensure that all read zero.

Machine damage from leakage CAUTION

Leaks result in loss of oil and reduced performance. Damage Dama ge or complete breakdown c an result.  

 

Test run after maintenance or service. Carry Car ry o ut a visu visual al check o f the machine.

10 --- 46

 

Maintenance Maintena Mai ntenance nce work may only be carried out:  

 

 

by persons trained in the machine and persons under the supervision of an expert, by experts, by an authorised KAESER KAESER service agent.

Work o n electrical devices devices may only be carried out in accordance with electrical regulations:  

 

 

10.2 10. 2

by persons trained in the machine under the supervision of an electrician, by an electrician, by an authorised KAESER KAESER service agent.

Mai Maint nten enan ance ce Sc Sche hedu dule le Maintenance intervals are recommendations only and should be adjusted to suit the installation and operating conditions. According to the way a machine is equipped, sensors and/or maintenance interval counters monitor the operational state of important functional devices. Necessary maintenance tasks are signalled by the SIGMA controller.  

Keep a log of all service work.

This enables the frequency of individual maintenance tasks to be compared with KAESER’s recommendations. A list is given in chapter 10.15.

10.2.1

Resett Resettin ing g maint maintenan enance ce int interva ervall co coun unters ters Maintenance interval counters indicate the operating hours between maintenance tasks. When a maintenance task is completed, reset the corresponding counter to its original value. See the SIGMA CONTROL service manual.

Pre --- condition: condit ion:   Maintenance Maintenance task task completed. Service Servi ce message reset. Activate password level 4.  

 

Select the appropriate entry from the maintenance menu. Select ’reset’ and ’y’ and confirm with the enter key.

10 --- 47

 

Maintenance 10.2.2

Regular Regular mainten maintenanc ance e work When operating conditions are unfavourable (e.g. dusty atmosphere) or when the equipment is heavily utilised, maintenance tasks must be carried out more frequently (shorter intervals).  

 

I nterval Weekly Every 1000 h Indicated by SIGMA CONTR CON TROL OL Indicated by SIGMA CONTR CON TROL OL but at least annually. Indicated by SIGMA CONTR CON TROL OL but at least every 3 years. Every 2000 h, but at least annually. Every 3000 h Variable (see below) Annua nnuallly

Heed controller maintenance messages. Have KAES KAESER ER service adjust the maintenance interval interval co unters to suit operating c onditions.

M aintenance tasks Chec k c o oling oil level. Clean o r renew the filter mats. Oil and air c oo ler maintenanc e. Heat rec o very system maintenanc e. Air filter maintenanc e.

see chapter 10.10.1 10.3.2 / 10.6 10.3 10.4 10.5

Change the o il filter.

10.12

Change the o il sep arato r c artrid g e.

10.14

Grease the mo to r bearing s.

10.7

Chec k the c oup ling. Change the c o oling oil.

10.8 10.11

Check heck tha that all elect lectri rica call conne connect ctiion ons s are tigh tight. t. Chec k the pressure relief valve. Chec k the oil and air c oo lers fo r leaks.

10.13 10.3

h = operating operating hours Tab. ab. 35

10.2.3 10. 2.3

Regula egularr main mainte tena nance nce work  work 

Oil cha chang nge e inte interv rvals als The The duty cycle and ambient ambient c onditions are important important criteria for the number and length of the change intervals.

Cool Co ola ant

SIGMA FLUID PLUS

Max Maximum perm permiissible ble oi oill chan change ge interv erval [operating hours / year] Favourable operating condiUnfavourable operating conditions* tions 6 000 / 1 9 000 / 3

SIGMA FLUID MOL

3 000 / 1

2 000 / 1

SIGMA FLUID FGL

3 000 / 1

2 000 / 1

2 000 / 1 3 000 / 1 SIGMA FLUID FGH * Cool to moderate ambien ambientt temperatures, temperatures, low humidity, humidity, high d uty c ycle Tab. ab. 36 Oi Oill change change in inte terv rval als  s 

10 --- 48

 

Maintenance 10.2.4 10. 2.4

Reg Regul ular ar se servi rvice ce work work Only authorised KAESE KAESER R service agents should carry out service work. When operating conditions are unfavourable (e.g. dusty atmosphere) or when the equipment is heavily utilised, service work must be carried out more frequently (shorter intervals).

I nterval Up to 12000 h Up to 12000 h, at the latest every 3 years Up to 36000 36000 h, at the latest every years Tab. ab. 37

M aintenance tasks Check valves. Change Cha nge the fan motor bearings bearings or the motor complete.

Change Change the drive drive motor bearin bearings. gs. Change Cha nge the coupling. Change the hose lines. Regula egularr serv service ice wor work  k 

10 --- 49

 

Maintenance 10.3 10. 3

Co Cool oler er Mai Maint nten enan ance ce

10.3.1 10. 3.1

Air Air coo cooli ling ng (opt (optio ion n K1) K1) Material:

 

brush vacuum cleaner

Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down. Check the cooler regularly Check regularly for c ontamination ontamination.. Frequency Frequency is mainly dependa dependant nt o n loc al operating conditions. Contamination causes overheating and machine damage.

Avoid dust disturbance. Wear breathing apparatus if necessary. Do not use sha sharp rp o bjects to clean clean the c ooler. ooler. The cooler could be damaged. A severely severely contaminate cont aminated d cooler c ooler should b e cleaned by a KAESER KAESER service agent.

Fig ig.. 17 1 2  

10.3.2

Cle lea ani ning ng th the e cooler  cooler 

Co oler   Brush  

Dry brush the cooler (1) and use a vacuum cleaner to suck up the dirt.

Filter Filter mat main mainten tenanc ance e (opti (option on K3) Material:

 

Warm water and household detergent Spare parts (as required)

switched off.off Pre --- condition: condit ion:   Machine Mains isolator locked Machine Machi ne cooled down.

10 --- 50

 

Maintenance

Fig ig.. 18 1 2 3

Cooler ooler filt filter er ma mats  ts 

Filter mat  Ret eta ain inin ing g fra frame  Fixing  

Removal  

Unlock the fixi fixings ngs (3). Use a screwdriver to turn the fixing 90˚ anti---clockwise.  

Remove the frame (2).

Cleaning Beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat in lukewarm water and household detergent then rinse thoroughly. Renew the mat if cleaning is not possible of has already been carried out five times.  

Replacing  

10.3.3

Replace the frame and close the fixings. Press Pre ss and turn the fixi fixings ngs 90˚ clockwise until they latch.

Water Water cooling cooling main mainten tenanc ance e (opti (option on K2) Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down. Check the cooler regularly Check regularly for leaks and c ontaminati ontamination. on. Freque Frequency ncy of c hecking is dependant on the characteristics of the cooling water. Contamination causes overheating and machine damage.

 

Observe the airend discharge temperature to detect any tendency to rise.

Cleaning:  

An authorised KAESE KAESER R service agent should clean the cooler coo ler when the airend airend discharge temperature is 10 ˚ C above the annual average. average.

Leakage Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak occurs, o il will run into the cooling water. water.  

 

Check the cooler visually for leaks. Have an authorised KAES KAESER ER service agent check the coo ler for internal leaks at least once a year.

10 --- 51

 

Maintenance 10.4

Int Intern ernal al H Heat eat Rec Recov overy ery Main Mainten tenan ance ce (o (opti ption on W2 / W3) Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down. Deposits in the heat exchanger in machines with heat recovery systems can adversely affect heat transfer. Check the heat exchanger regularly for leaks and contamination. Frequency of checking is dependant on the characteristics of the heat transfer medium.

Contamination Have an authorised KAES KAESER ER service agent clean the heat exchanger as soon as a pressure drop in the heat transfer medium is detected.

 

Leakage If a leak occurs, c ooling oil c an flow into the heat heat transfe transferr medium as pressure the cooling oil circuit is generally higher. Check the heat exchanger visually for leaks.

 

Have an authorised KAES KAESER ER service agent check the heat exchanger for internal leaks at least once a year.

 

10.5

Ai Airr Filt Filter er Main Mainten tenanc ance. e. Material:

 

Compressed air Spare parts (as required)

Pre --- condition: condit ion:   Machine switched off Mains isolator locked off Machine Machi ne cooled down.

Fig. 19 1 2

Air filt filter er ma main inte tena nance. nce.

Retaining c lip Co ver  

3

Air filter c artrid g e  

10 --- 52

 

Maintenance Open the air filter housing: Pulll the retaining Pul retaining clips (1) outwards and remove the cap (2).  

Pull out the air filter cartridge (3) by turning lightly.

 

Clean the sealing surfaces and the air filter housing.

 

Do not no t wet ---c lean the air filter element.

Clean the air filter cartridge by tapping Renew the cartridge after two years or after it has been cleaned five times. Tap the cartridge on the end a number of times with the palm of the hand.

 

Clean the sealing faces.

 

Cleaning the air filter cartridge with compressed air Use dry compressed air at not more than 5 bar to blow dirt from the air filter cartridge from inside to outside. outside.  

Close the air filter housing Insert the filter cartridge.

 

Push on the housing and close the retaining clips.

 

Close all access doors and replace all cover panels. Switch on the power supply and reset the maintenance interval counter.

 

 

10.6

Fi Filter lter mat main maintenan tenance ce (cont (control rol cabi cabinet net ven ventil tilator) ator) Material:

 

Warm water and household detergent Spare parts (as required)

Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down.

Fig. 20 1 2

Cont Contro roll cabine cabinett vent ventil ilat ator  or 

Venti entila lato torr gr gril ill l  Filter mat 

10 --- 53

 

Maintenance Removal Remove the ventilator grill (1) and the filter mat (2).

 

Cleaning Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat in lukewarm water and household detergent then rinse thoroughly. Renew the mat if cleaning is not possible of has already been carried out five times.

 

Replacing La Lay y the filter filter mat in the frame and push on the grill to latch.

 

10.7

Elect Electri ric c mo moto torr mai maint ntena enanc nce e Material:

 

Bearing grease Cleaning rags

Pre --- condition: condit ion:   Machine running.

Hot components --- danger of burning CAUTION

 

 

Wear We ar long ---arm clothing and gloves. g loves. Work carefully.

Compressor motor The motor bearings are fitted with grease nipples. High ---temp -temperature erature grease ESS ESSO O UNIREX N3 should be used for re ---g -greasreasing the motor bearings. Bearing damages caused by the use of other brands of grease are excluded from the warranty.

Fig. 21 1  

Compr Compres essor sor motor motor main mainte tena nance  nce 

Grease ease ni nipp pplle  Clean the grease nipple (1) with a rag.

Apply the quantity of grease as given on the motor nameplate.  

 

 

Grease both bearings. Close all access doors; replace and secure all removable panels. Switch on the machine and reset the maintenance interval counter.

Fan motor Fan motor bearings are permanently greased and need no further greasing.

10 --- 54

 

Maintenance 10.8

Ch Check eckin ing g the the Cou Coupl plin ing g Danger of injury from rotating coupling! WARNING Severe Severe inj injury ury c ould result from touching the c oupling while it is rotating. rotating. Neverr switch the machine on without the guard in place over the Neve coupling.  

The coupling must be carefully inspected at regular intervals. A defective coupling is recognisa recognisable ble by:  

 

 

noisy running, surface cracks, colour c hange. hange.

Fig ig.. 22 1 2

Che hecki cking ng th the e Coup Coupli ling  ng 

Safet ety y scree screen  n  Co up ling  

Check for uneven or noisy running  

 

Switch Swi tch the machine on. Check Che ck the coupling (2) for noisy or uneven uneven running. running.

Check for damage Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down.  

 

 

 

 

Remove the fixing screws from the safety screen (1). Turn the coupling my hand and look for damage or colour change. Have a damaged damaged coupling c oupling c hanged by an authorised KAESER KAESER Service agent. agent. Refit the safety screen. Close all access doors and replace all cover panels.

10 --- 55

 

Maintenance 10.9

Ven enti ting ng the the Mach Machin ine e Manu Manuall ally y Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine Machi ne cooled down.

Compressed air can cause injury or death. WARNING

Compressed air and devices under pressure can injure or cause death if the contained energy of the air is released suddenly or uncontrolled. After shutting down the compressor and venting the oil separator tank there is still pressure on the check valve from the air main.  

 

 

Close the shut---off valve provided by the user to isolate the machine from the air main. Vent the oil separator tank. Vent the air aftercooler to completely depressurise the system between the user’s shut---off valve and the minimum pressure/check valve.

Escaping oil mist is damaging to health. CAUTION  

 

 

Do not direct the maintenance hose at a person while venting. Do not inhale oil mist or vapour. Avoid contact with skin and eyes.

Before undertaking any maintenance or service work on the pressure system the machine must be isolated from the air system and completely vented. The machine is vented in three stages:  

 

the oil circuit vents automatically when the machine is switched off, air is vented manually from the oil separator tank,

 

air is vented manually from the air cooler.

Venting  

Close the user’s shut---off valve between the machine and the air main. If no shut---off valve is provided, the complete air system must be vented. The hose coupling, shut---off valve and maintenance hose lie beneath the oil separator tank.

10 --- 56

 

Maintenance

Fig. 23 1 2

3  

Venti entila late te th the e machin machine. e.

Hos ose e coupl couplin ing g (ai (air coo cooller ven entting ng)) Pressure g auge Pr

6 7

Mal Male ho hose se cou coupl pliing ng/f /fiitting  Shut --- o ff valve   A: closed  B: open  Main Mainte tena nance nce ho hose  se 

Hose Hose coupling coupling (oil sepa separa rator tor ta tank nk ve ven-  n-  8 ting) Check that the oil separator tank pressure gauge reads zero.

After automatic venting the pressure gauge does not read zero?  

 

Make sure that the shut---off valve is closed. If manual venting does not bring the oil separator tank pressure gauge to zero, call KAESER KAESER service.

Manually venting the oil separator tank  

 

 

With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (3). Open the shut---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut---off valve.

Manually venting the compressed air cooler  

 

 

With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (1). Open the shut---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut---off valve.

10.10 Chec Checkin king g and T Toppi opping ng u up p the Coo Coolin ling g Oil 10.10.1 Check cooli cooling ng oil level. level. Pre --- condition: condit ion:   Machine has been been running at least five minutes minutes under load. (minimum (mini mum 50 Hz for machines machines under frequency c ontrol). Danger of burning from hot surfaces! CAUTION

Skin burns are possible.  

 

Wear We ar long ---arm garments and protective protec tive gloves. Work carefully.

10 --- 57

 

Maintenance

Fig ig.. 24 2 3 4 5  

Che heck ck coolin cooling g oi oill le lev vel el..

Oil sep arator tank Oil level ind ic ato r Ind ic ator marking s Gree een n zon one  e 

min OK max

Minimum o il level   Oil level o p timum   Oil level maximum  

Readout oil level.

When the indicator shows minimum level, top up the oil.

10.10.2 Topping up tthe he cooli cooling ng oil oil Material:

 

Cooling Cooling oil

Pre --- condition: condit ion:   Machine switched off Mains isolator locked off Machine Machi ne cooled down.

Danger of explosion from oils and lubricants! WARNING

Danger of explosion from oil mist and vapours.  

Fire, naked flame and smoking are forbidden!

Damage to the machine from unsuitable oil CAUTION  

 

Never mix different types of oil. Top up only with the same type of oil as already in the machine.

Venting  

Close the user’s shut---off valve between the machine and the air main. If no shut---off valve is provided, the complete air system must be vented. The hose coupling, shut---off valve and maintenance hose lie beneath the oil separator tank.

10 --- 58

 

Maintenance

Fig ig.. 25 1 2 3

4  

Toppin opping g up th the e coolin cooling g oi oil l 

Hose ose co cou upl pliing (air coo cooller venting) Pressure g auge Pr Hose Hose coupling coupling (oil sepa separa rator tor ta tank nk ve ven-  n-  ting)

5 6 7

Oil level indi dica cattor  Male ho se c o up ling/fitting   Shuthut----off -off valve  lve  A: closed 

B:aopen  Oil filling p o rt with p lug 8 M intenanc e ho se   Check that the oil separator tank pressure gauge (2) reads zero.

After automatic venting the pressure gauge does not read zero?  

 

Make sure that the shut---off valve is closed. If manual venting does not bring the oil separator tank pressure gauge to zero, call KAESER KAESER service.

Manually venting the oil separator tank  

 

 

With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (3). Open the shut---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut---off valve.

Manually venting the compressed air cooler With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (1).  

 

 

Open the shut---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut---off valve.

Topping up the cooling oil  

 

 

Open the filler plug (4) slowly. Top up the cooling oil. Replace the plug gasket if necessary and re---insert the plug.

Start the machine and carry out a test run  

 

 

 

 

Close all access doors; replace and secure all removable panels. Open the user’s shut---off valve between the machine and the air main. Start the machine and allow it to idle for at least one minute. Then switch to LOAD. After about five minutes, check the oil level and top up if necessary. Carry out a visual check for leaks.

10 --- 59

 

Maintenance 10.11 Chan Changin ging g the Cooli Cooling ng Oil Material:

 

Cooling Cooling oil Have the oil container ready.

Thoroughly drain the oil from the separator tank, the cooler and the heat recovery system if fitted.

Dispose of the old oil in accordance with local environment protection regulations. Danger of burning from hot components and oil. CAUTION

 

 

Fig. 26

Wear We ar long ---arm clothing and gloves. g loves. Work carefully.

Chan Changing ging the Cool Cooling ing Oil, Oil, Oil Oil Sepa epara rator tor Tan ank  k 

1 2

Hose ose coupl coupliing (a (air ir cool cooler ven entting ng)) Pressure g auge

6 7

Male Male ho hos se coupl couplin ing/ g/ffit ittting  Shut --- off valve   A: closed  B: open 

3

Hose Hos coupling (oil sepa separa rator tor ta tank nk ve ven-  n-  ting)e coupling Oil filling p o rt with p lug Oil level ind ic a atto r

8

Main Maintten ena ance hos ose  e 

9 10 11

Ho se c o ou up ling (oil d rain) Shut --- o offf valve (venting line) Shut-hut---off valve valve (oil drain) drain)

4 5

Compressed air helps to expel the oil. This pressure can be generated by the machine itself. Alternatively, an external source of compressed can be used. External air is necessary when:  

 

the machine is not operational the machine is to be restarted after a long standstill period.

Oil changing with help from internal pressure Pre --- condition: condit ion:   Machine has been running at least five minutes under LOA LOAD. D. Machine is switched off. Machine fully vented (no pressure). Pressure gauge on the oil separator tank indicates zero.

10 --- 60

 

Maintenance  

 

 

 

 

Close the shut---off valve (10) in the venting line. Start the machine in idle and watch the oil separator tank pressure gauge (2) until it reads 3---5 bar. Switch the machine off. Switch Swi tch off and lock out the main supply isolator isolator.. Wait at least two minutes for oil to flow back to the separator tank.

Alternative: Oil changing with help from an external pressure source Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine fully vented (no pressure). Pressure gauge on the oil separator tank indicates zero. External source of compressed air available.  

 

Close the shut---off valve (10) in the venting line. With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (3).

 

 

 

Connect the maintenance hose to an external air supply. Open the shut---off valve (7) until the pressure gauge on the oil separator tank reads 3 --- 5 bar. Close the shut---off valve (7) and withdraw the hose fitting from the coupling.

Draining the oil from the separator tank Contact KAESER KAESER service if condensate is detected detected in the oil. It is necessary to adjust the airend discharge temperature to suit operating conditions.  

 

 

 

 

 

Have the oil container ready. With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (9). Place the end of the maintenance hose in the oil container and secure it in place. Open the shut---off valve (11). Open the shut off valve (7) in the maintenance hose slowly and close when air escapes. Close the shut---off valve (11) and unplug the hose.

10 --- 61

 

Maintenance Draining the oil from the cooler

Fig ig.. 27 1 2 3  

 

 

 

 

 

 

Cha hang ngin ing g th the e Cool Coolin ing g Oil 

Oil c o oler Hose c o ou up ling (o il d rain) Shut-hut---off va valv lve  e 

6 7

Male ho se c o up ling/fitting   Shut --- o offf valve  

Have the oil container ready. With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (2). Place the end of the maintenance hose in the oil container and secure it in place. Open the shut---off valve (3). Open the shut---off valve (7) slowly and allow oil and air to drain completely. Check that the oil separator tank pressure gauge reads zero. Close the shut---off valve (2) and unplug the hose.

Filling with cooling oil  

 

Open filler plug (4, Fig. 26) slowly. Fill with oil. Machines with heat recovery systems need correspondingly more oil.

 

Check the plug and gasket for damage and re---insert the plug.

Start the machine and carry out a test run  

 

Close all access doors; replace and secure all removable panels. Open the user’s shut---off valve between the machine and the air main.

10 --- 62

 

Maintenance Switch on the power supply and reset the maintenance interval counter.

 

Allow the machine to idle for at least one minute. Then switch to LOAD.

 

After about five minutes, check the oil level and top up if necessary.

 

Carry out a visual check for leaks.

 

10.12 Oil filter filter main maintenan tenance ce Material:

 

Spare parts Have the oil container ready.

Pre --- condition: condit ion:   Machine switched off Mains isolator locked off Machine fully vented (no pressure). Pressure gauge on the oil separator tank indicates zero.

Danger of burning from hot components and oil. CAUTION

 

 

Fig. 28 1 2

Wear We ar long ---arm clothing and gloves. g loves. Work carefully.

Chan Changin ging g th the e Oi Oill Fil ilte ter  r 

Oil fil iltter  Di Dire recti ction on to unscr unscrew  ew 

Dispose of parts and materials contaminated with oil in accordance with local environment protection regulations.  

 

Unscrew the oil filter anti---clockwise, catch oil spillage and dispose of correctly. Lightly oil the new oil filter gasket. Screw on the new filter using hand pressure only. Do not use any tool.

 

The oil filter is turned clockwise to tighten.

10 --- 63

 

Maintenance Start the machine and carry out a test run  

 

Close all access doors; replace and secure all removable panels. Open the user’s shut---off valve between the machine and the air main.

 

 

 

 

Switch on the power supply and reset the maintenance interval counter. Allow the machine to idle for at least one minute. Then switch to LOAD. After about five minutes, check the oil level and top up if necessary. Carry out a visual check for leaks.

10.13 Chec Checkin king g th the e Pres Pressur sure e Rel Relief ief Valv alve. e. Pre --- condition: condit ion:   Machine switched off. Activate password level 4. In order to check the pressure relief valve, the machine’s working pressure is raised above the blowoff pressure of the valve.

There is danger of bursting if the permissible working pressure is exceeded. WARNING Noise from the pressure relief valve blowing off. Danger of scalding from hot oil. Danger of injury from bursting components or the rele release ase of compressed air.  

 

 

 

Close all access doors; replace and secure all removable panels. Wear ear and eye protection. Work carefully. Abort the test if the working pressure reaches 10% above the blowoff pressure of the valve.

Carry out the test exactly as described in the SIGMA CONTROL manual. Blowoff protection and system p res ressure sure monitoring are switched off during the test. The The machine may only be operated with a correctly functioning pressure relief valve.  

 

 

 

 

 

Close the user’s shut---off valve between the machine and the air main. Observe the pressure indicator on the SIGMA controller and call up the test function. Stop the test as soon as the pressure relief valve blows off or working pressure reaches 10% above the blowoff set point. Replace a defective pressure relief valve. Deactivate the test function. Open the user’s shut---off valve between the machine and the air main.

10 --- 64

 

Maintenance 10.14 Chan Changin ging g tthe he Oil Separat Separator or Cartr Cartridge idge Material:

 

Spare parts Precision pressure gauge Cleaning rags

Pre --- condition: condit ion:   Machine switched off. Mains isolator locked off Machine fully vented (no pressure). Pressure gauge on the oil separator tank indicates zero. Machine Machi ne cooled down. The life of the oil separator cartridge is influenced by: contamination in the air drawn into the compressor,

 

adherence to the schedule of oil and air filter changes,

 

Fig. 29 14 15 16 17  

 

 

 

Chan Changing ging the Oil Oil Sepa epara rator tor Cart Cartri ridge  dge 

Cover Dirt trap Air pipe Retaining sc rew

19 20 21 23 25

Pipe fitting   Fitting   Gasket   Oil sep arator c artridg e   Minimum Minimum pressu pressure re/check /check va valv lve  e 

Unscrew the fitting (20) and carefully Unscrew carefully put the parts to one side; pull out the copper pipe at item (15). Unscrew Unscre w the fittings (19) from the ends of the air pipe (16). Withdraw the air pipe from the minimum pressure/check valve (25) and push carefully to one side. Remove the cover retaining screws (17) and carefully lift the cover (14). The oil separator element cannot be cleaned.

10 --- 65

 

Maintenance Dispose of parts and materials contaminated with oil in accordance with local environment protection regulations.  

 

 

 

 

 

Take out the old oil separator element (23) together with the gaskets (21) and dispose of according to environmental regulations. Wipe all sealing faces with a cleaning rag. Insert the new oil separator cartridge with gaskets and re---fix the cover. Renew the dirt trap (15) strainer and O---ring. Connect the air pipe to the minimum pressure/check valve. Replace and tighten all fittings.

Start the machine and carry out a test run  

 

 

 

 

Close all access doors; replace and secure all removable panels. Open the user’s shut---off valve between the machine and the air main. Switch on the power supply and reset the maintenance interval counter. Allow the machine to idle for at least one minute. Then switch to LOAD. Carry out a visual check for leaks.

10 --- 66

 

Maintenance 10.15 Lo Loggi gging ng Mainten Maintenanc ance e Wo Work rk Machine number: Date

Tab. 38

Maintenance task carried out

Main Mainte tena nance nce lo log  g 

Operating hours

Signature

10 --- 67

 

Spares, Operating Materiels, Service 11

Sp Spare ares, s, Opera Operati ting ng Mat Mater erial ials, s, Serv Servic ice e

11.1 11. 1

No Note te the the na name mepl plat ate e Take data from the nameplate for all enquiries and spare parts orders.

11.2

Orderi Ordering ng Mainten Maintenance ance Part Parts s and Operati Operating ng Material Materials s Personal injury or machine damage may result from the use of unsuitable spare parts or operating materials. CAUTION Unsuitable or poor quality maintenance parts and operating materials may damage dama ge 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 authorised KAESER KAESER service agent carry out regular r egular maintenance.

KAESER maintena KAESER maintenance nce parts and operating o perating materials correspond to the original. These These are correct for use in our machines. machines.

Compressor Name Air filter c artrid g e Filter mat, c o ntro l c ab inet fan Filter mat (c oo ler) Oil filter Oil sep arato r c artridg e Coo ling o il Bearing grease [g] Tab. ab. 39

11.3 11. 3

Quantity 1 2 1 1 1 1

material number 1250 1100 1050 1200 1450 1600

100 400

9.0915.0 6.3234.0

 

Machin Machine e main mainte tena nance nce part parts  s 

Mai Maint nten enan ance ce Co Con ntrac tractt  

Sign a maintenance maintenance co ntract with an authorised KAESER KAESER service agent.

This ensures the utmost reliability and availability of your compressed air supply system.

11.4 11. 4

Ser Serv vice ice Add ddres resse ses s Address of KAESER KAESER agents are given at the end of this manual.

11.5

Spar Spare e Par Parts ts for Ser Servi vice ce an and d Rep Repair air These spare parts lists are intended for trained personnel. They contain important information for preventive service. Service Service and repair work not describe described d in the this manual should should only be carried out b y a KAESER KAESER service workshop or one authorised by b y KAESE KAESER. R.

11 --- 68

 

De---commissioning, Storage and Transport 12

DeDe --- comm commiss ission ioning ing,, Stor Storage age and Trans Transpor portt

12.1

De ---comm -commis issi sion onin ing g De----c ommissioning is necessary when: Dethe machine will not be needed for some time,  

 

 

 

the machine is to b e moved to another another location, the machine is no longer needed, the machine is to b e scrapped.

Temporarily out of service Pre --- condition: condit ion:   The machine can be started at regular inte intervals. rvals.  

Run the machine once a week under load for at least 30 minutes to ensure corrosion protection.

Out of service for a considerable period Pre --- condition: condit ion:   When When running for the last time before taking out of service the machine should have run under load for at least 30 minutes. Machine switched off and fully vented. Main Mai n supply isolator isolator switche switched d off and locked.  

 

 

12..2 12

All Allow ow the machine to coo l down completely completely. In water---cooled machines, disconnect the water supply and drain all water from the machine. Disconnect all air and electrical connections.

Pac ack king Material:

 

Desiccant Plastic Pla stic sheeting Wooden transport crate

Pre --- condition: condit ion:   Machine is de ---c ommissioned. Machine dry and cool.  

 

Place desiccant inside the machine cabinet. Wrap the machine in plastic sheeting.

Transport packing A wooden c rate is required required for overland overland transport to protect the machine from mechanical damage. Consult an authorised KAES KAESER ER service agent for advice on packing for sea or air transport.

12..3 12

Storag age e Pre --- condition: condit ion:   The machine is a adequately dequately packed.  

 

Store the machine in a dry, frost---free room. Prevent entry of moisture and condensation.

12 --- 75

 

De---commissioning, Storage and Transport 12.4 12. 4

Tra rans nspo port rtin ing g Use only a fork truck or lifting cradle. Take weight and centre of gravity into consideration. The centre of gravity is shown in the drawing in chapter 13.2.3. The water cooling system of water---cooled machines must be drained completely completel y if there is danger of frost.

Fork truck Pre --- condition: condit ion:   The whole machine is over the forks.

Fig. 30

Trans ranspor portt by for fork k truck  truck 

Lifting cradle Pre --- condition: condit ion:   No pressure on the sides sides of the machin machine e cabinet. cabinet.

Fig. 31

12..5 12

Trans ranspor portt by lift liftin ing g cradle  cradle 

Dis Disposal Pre --- condition: condit ion:   Machine is de ---c ommissioned. When disposing of a machine, drain out all liquids and remove dirty filters.

Parts contaminated with cooling oil must be disposed of in accordance with local environment protection regulations.  

 

 

Completely Comple tely drain the c ooling oil from the machine. Remove used ail filter and separator cartridge. Hand the machine over to an authorised disposal expert.

12 --- 76

 

Annex 13

Annex

13.1 13 .1

Co Con nform formit ity y Machines with CE mark conform to European directives and may be operated in the EU. A Declaration of Conformity is provided with the machine.

13.2 13. 2

Diagr Diagram ams s an and d Dr Draw awin ings gs

13.2.1

Pipelin Pipeline e and and instr instrume ument nt flo flow w diagram diagram (P&I dia diagrams grams))

13 --- 77

 

Appendix 13.2.2

Pipelin Pipeline e and and instr instrume ument nt flo flow w diagram diagram (opti (option on C1)

13 --- 83

 

Appendix 13.2.3 13. 2.3

Dim Dimen ensi sion onal al dra drawi wing ng

13.2.3.1 Air cooling cooling (option K1) K1)

13 --- 89

 

Appendix 13.2.3.2 Water cooling cooling (option K2)

13 --- 92

 

Appendix 13.2.4 13. 2.4

Elect Electric rical al diagra diagram m

13 --- 95