SERVICE MANUAL

Screw Compressor
Model: ASK T SIGMA CONTROL BASIC
No.: 9_5717_01E

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg PO Box 2143 GERMANY Tel. + 49 ---(0)9561 ---6400 Fax + 49 ---(0)9561 ---640130
http://www.kaeser.com
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1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

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

2 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

2.1 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.3 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.4 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.5 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.6 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.7 Motors and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.7.1 Compressor motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.8 Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.8.1 Recommended cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.8.2 Cooling Oil Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9.2 Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.10 Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8

3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9

3.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.3 User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.5 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.5.1 Danger of electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.5.2 Danger from rotating parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11
3.5.3 Hazards from compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11
3.5.4 Hazards from spring forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.5.5 Further dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.6 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.7 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.7.1 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.7.2 Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.7.3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.8 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14

4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

4.1 Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.1.1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

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4.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18

4.2.1 Machine mountings (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.3 Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.3.1 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.3.2 Tasks of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.3.3 Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.3.4 Modulating control (option C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.3.5 Refrigeration dryer control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.5 Keys and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.6 Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.6.1 Display field layout (Display, Position 12, Fig. 6) . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.6.2 Display of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
4.6.3 Parameter setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 23
4.6.4 Alarm and warning message recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 24

5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25

5.1 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
5.2 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
5.2.1 Place of installation and space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
5.2.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26
5.2.3 Operating in a compressed air network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
6.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
6.2 Report any Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
6.3 Install the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
6.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28
6.5 Condensate Drainage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.6.1 Machine fixing (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29

7 Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30

7.1 Before Initial Start ---up (or Recommissioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.2 Check installation and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.3 Setting the overload protection cut ---out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.4 Pour cooling oil into the inlet port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.5 Checking Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.6 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.7 Setting System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 32

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.1 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.1.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.1.2 Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.1.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.2 Switching Off in an Emergency and Switching On Again . . . . . . . . . . . . . . . . . 8 --- 34
8.3 Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . . 8 --- 35
8.3.1 Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.4 Shutting Down the Refrigeration Dryer (option T3) . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35

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9 Fault Recognition and Rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36

9.1 Alarm messages on the controller (machine off) . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.2 Warning messages on the controller (yellow LED illuminated) . . . . . . . . . . . . . 9 --- 37
9.3 Miscellaneous faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 40
10.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 40
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 41
10.2.1 Resetting maintenance interval counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 41
10.2.2 Regular Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 42
10.2.3 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 43
10.2.4 Regular Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 43
10.3 Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 44
10.4 Filter mat maintenance (control cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45
10.5 Maintain the Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45
10.6 Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 46
10.7 Maintain the Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 46
10.7.1 Check the belts and their tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 46
10.7.2 Changing the belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 47
10.8 Check the Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 47
10.9 Vent the Machine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 48
10.10 Check and Top ---up the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
10.10.1 Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
10.10.2 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.11 Change the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.12 Oil filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.13 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
10.14 Refrigeration dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.14.1 Cleaning the refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.14.2 Check condensate drainage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.14.3 Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.15 Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 61

11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62

11.1 Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.2 Ordering Maintenance Parts and Operating Materials . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.3 Maintenance Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.4 Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62
11.5 Spare Parts for Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62

12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . 12 --- 68

12.1 De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 68
12.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 68
12.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 68
12.4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69
12.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69

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13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 70
13.1 Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 70
13.2 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 70
13.2.1 Pipeline and instrument flow diagram (P&I diagrams) . . . . . . . . . . . . . . . . . 13 --- 70
13.2.2 Pipeline and instrument flow diagram (option C1) . . . . . . . . . . . . . . . . . . . . 13 --- 76
13.2.3 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 82
13.2.4 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 85

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Fig. 1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15

Fig. 2 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
Fig. 3 Refrigeration dryer and condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
Fig. 4 Machine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
Fig. 5 Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
Fig. 6 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Fig. 7 Display layout (Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Fig. 8 Installation recommendation, dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
Fig. 9 Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
Fig. 10 Control Transformer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28
Fig. 11 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
Fig. 12 Condensate drainage, dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
Fig. 13 Inlet valve oil filling port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
Fig. 14 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
Fig. 15 Switching off in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
Fig. 16 Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . . . . 8 --- 35
Fig. 17 Cooler filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 44
Fig. 18 Control cabinet ventilation grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 45
Fig. 19 Air filter maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 46
Fig. 20 Ventilate the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 49
Fig. 21 Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
Fig. 22 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
Fig. 23 Changing the Cooling Oil, Oil Separator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
Fig. 24 Changing the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
Fig. 25 Change the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
Fig. 26 Changing the oil separator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
Fig. 27 Refrigeration dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Fig. 28 Test condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Fig. 29 Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
Fig. 30 Transport by fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69
Fig. 31 Transport by lifting cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 69

v
 Table Directory
Chapter --- page

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

Tab. 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 3 Machine weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 4 Machine temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 5 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 6 Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 7 Delivery (50 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 8 Delivery (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 9 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 10 Compressor motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 11 Compressor motor rated speed (50 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 12 Compressor motor rated speed (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 13 Recommended cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 14 Cooling oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 15 Supply 230V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 16 Supply 400V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 17 Supply 230V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 18 Supply 380V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 19 Supply 440V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 20 Supply 460V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 21 Refrigeration dryer models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 22 Refrigeration dryer, compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 23 Refrigeration dryer, refrigeration system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 24 Inspection schedule for Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
Tab. 25 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
Tab. 26 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Tab. 27 Display field (Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Tab. 28 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
Tab. 29 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 24
Tab. 30 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 24
Tab. 31 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26
Tab. 32 Checklist, installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
Tab. 33 SIGMA CONTROL BASIC alarm messages and Rectification Measures . . . . . . 9 --- 37
Tab. 34 SIGMA CONTROL BASIC alarm messages and Rectification Measures . . . . . . 9 --- 37
Tab. 35 Miscellaneous events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
Tab. 36 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 42
Tab. 37 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 43
Tab. 38 Regular service work intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 43
Tab. 39 Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 61
Tab. 40 Machine maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 62

vi
 Regarding this Document

1 Regarding this Document

1.1 Handling the Document

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

1.2 Further Documents

Included with this Service Manual are documents intended to assist in safe and sure oper-
ation of the machine:


certificate of acceptance / operating instructions for the pressure vessel


manufacturer’s declaration or declaration of conformity in accordance with applicable
directives
Make sure all documents are to 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 service manual is copyright protected. Queries regarding use or duplication of the
documentation should be referred to KAESER. Correct use of information will be fully sup-
ported.

1.4 Symbols and Identifications

1.4.1 Warning notices

Here is a notice warning of danger.

DANGER Here are consequences of ignoring the warning notice.

The word ’Danger’ indicates that death or severe injury can result from ig-
noring the notice.
Always read and diligently comply with warning notices.

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

Signal word Meaning Consequences of ignoring the warning

DANGER Warns of imminent threa- Death or severe injury or serious damage to
tening danger the machine is possible
WARNING Warns of possible threate- Death or severe injury or serious damage to
ning danger the machine is possible
CAUTION Warns of a possibly Light injury or slight damage possible
dangerous situation

1 --- 1
 Regarding this Document

1.4.2 Miscellaneous notices and symbols

Here is a task to be carried out.

This symbol identifies environmental protection measures.

This indicates important information.

1 --- 2
 Technical Specification

2 Technical specification
The model designation and important technical information is to be found on the machine
nameplate. The nameplate is found inside the machine. It is fixed to the outside of the con-
trol cabinet or inside the cabinet door.
Please transfer data from the nameplate.

Model
Material (part) no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature
Tab. 1 Nameplate

A list of options fitted helps to relate the information in this service manual to your machine.
Please enter details of the options here:
A summary of the included options helps to relate the service manual information to your
machine.
Please enter details of options.

Option Code Existing

Machine mountings H1
Modulating control C1
Transformer power supply for refrigeration T2
dryer
Refrigeration dryer T3
Tab. 2 Options

2.1 Weight
Maximum weights are shown. Actual weights of individual machines are dependent on
equipment fitted.

ASK 27 ASK 32
Weight [kg] 465 480
Tab. 3 Machine weights

2.2 Temperature
ASK 27 ASK 32
Minimum cut ---in tempera- 3 3
ture [˚ C]
Typical airend discharge 75 --- 100 75 --- 100
temperature during oper-
ation [˚ C]
Max. airend discharge 110 110
temp. (automatic safety
shut ---down) [˚ C]
Tab. 4 Machine temperatures

2 --- 3
 Technical Specification

2.3 Ambient Conditions

ASK 27 ASK 32
Maximum elevation [m] 1000 1000
Ambient temperature [˚ C] 3 – 45 3 – 45
Inlet air / cooling air tem- 3 – 45 3 – 45
perature [˚ C]
Maximum relative inlet air 100 100
humidity at 31 ˚ C [%]
Maximum relative inlet air 50 50
humidity at 45 ˚ C [%]
* Higher elevation permissible only after consultation with the manufacturer
Tab. 5 Ambient Conditions

2.4 Pressure
See nameplate for maximum working pressure

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

Maximum working pres- ASK 27 ASK 32

sure [bar]
8 11.5 11.5
8.5 11.5 11.5
11 15 15
15 16 16
Tab. 6 Pressure relief valve setting

2.5 Delivery
Delivery [m3/min] (50 Hz):

Maximum working pres- ASK 27 ASK 32

sure [bar]
8 2.60 3.15
11 2.17 2.65
15 1.68 2.03
Tab. 7 Delivery (50 Hz)

Delivery [m3/min] (60 Hz):

Maximum working pres- ASK 27 ASK 32

sure [bar]
8.5 2.60 3.15
11 2.17 2.65
15 1.68 2.03
Tab. 8 Delivery (60 Hz)

2.6 Sound Pressure Level

Operational state

2 --- 4
 Technical Specification

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

ASK 27 ASK 32
Sound pressure level 66 68
(50Hz) [dB(A)]
Sound pressure level 67 69
(60Hz) [dB(A)]
Tab. 9 Sound Pressure Level

2.7 Motors and Performance

2.7.1 Compressor motor

ASK 27 ASK 32
Rated power [kW] 15 18.5
Enclosure protection IP 55 IP 55
Tab. 10 Compressor motor data

Rated speed [rpm] (50Hz)

Working pressure [bar] ASK 27 ASK 32

8 2945 2950
11 2945 2950
15 2945 2950
Tab. 11 Compressor motor rated speed (50 Hz)

Rated speed [rpm] (50Hz)

Working pressure [bar] ASK 27 ASK 32

8.5 3555 3560
11 3555 3560
15 3555 3560
Tab. 12 Compressor motor rated speed (60 Hz)

2.8 Cooling oil

Ordering: see ’Spare Parts, Operating Materials, Service’ chapter 11.

2.8.1 Recommended cooling oil

A sticker showing the type of oil filled is to be found near the oil separator filling port.

SIGMA SIGMA SIGMA

FLUID PLUS / S--- 460 FLUID MOL FLUID FGL / FGH
Description Synthetic oil Mineral oil Synthetic oil
Application: Standard oil for all ap- Standard oil for all Specially for use in
plications except in applications except compressors where
connection with foods- in connection with the air comes in direct
tuff. foodstuff. contact with foodstuff.
Especially suitable
for lightly utilized
machines.

2 --- 5
 Technical Specification

SIGMA SIGMA SIGMA

FLUID PLUS / S--- 460 FLUID MOL FLUID FGL / FGH
Authorization — — USDA H–1, NSF
Approved for the
manufacture of foods-
tuff packaging, meat
and poultry proces-
sing and other food
processing.
Viscosity at 70 mm2/s 44 mm2/s 50.7 / 70 mm2/s
40 ˚ C (DIN 51562 ---1) / (DIN 51562 ---1) (D 445; ASTM test)
45 mm2/s
(D 445; ASTM test)
Viscosity at 10.6 mm2/s 6.8 mm2/s 8.2 / 10.4 mm2/s
100 ˚ C (DIN 51562 ---1) / (DIN 51562 ---1) (D 445; ASTM test)
7,2 mm2/s
(D 445; ASTM test)
Flash point 260 ˚ C (ISO 2592) / 220 ˚ C 254 ˚ C
238 ˚ C (ISO 2592) (D92; ASTM test)
(D 92; ASTM test)
Density at 15 ˚ C 843 / 864 kg/m3 — —
(ISO 12185)
Pour point ---39 ˚ C ---33 ˚ C —
(ISO 3016) / (ISO 3016)
---46 ˚ C
(D 97; ASTM test)
Demulsibility at 30 min — —
54 ˚ C (ISO 6614) /
40/40/0/10 min
(D1401; ASTM---Test)
Tab. 13 Recommended cooling oil

2.8.2 Cooling Oil Volume

ASK 27 ASK 32
Total charge [l] 11.0 11.0
Top ---up volume [l] 2.0 2.0
(minimum --- maximum)
Tab. 14 Cooling oil volume

2.9 Power supply

See electrical diagrams in chapter 13.2.4.

2.9.1 Power supply

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

2 --- 6
 Technical Specification

2.9.2 Power supply specifications

The following conductor cross---sections (multicore Cu) and fusing (HRC fuse slow blow)
are given according to VDE 0100, parts 430 and 523, for ambient temperatures of 30 ˚ C,
non ---standard cable laying 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.
Rated power supply 230V 10%, 3 --- ph, 50Hz

ASK 27 ASK 32
Pre---fuse [A] 63 80
Supply line [mm2] 4x16 4x25
Consumption [A] 57 68
Tab. 15 Supply 230V/3/50Hz

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

ASK 27 ASK 32
Pre---fuse [A] 35 50
Supply line [mm2] 4x6 4x10
Consumption [A] 32 39
Tab. 16 Supply 400V/3/50Hz

Rated power supply 230V 10%, 3 --- ph, 60Hz

ASK 27 ASK 32
Pre---fuse [A] 63 80
Supply line [mm2] 4x16 4x25
Consumption [A] 58 70
Tab. 17 Supply 230V/3/60Hz

Rated power supply 380V 10%, 3 --- ph, 60Hz

ASK 27 ASK 32
Pre---fuse [A] 50 50
Supply line [mm2] 4x10 4x10
Consumption [A] 36 43
Tab. 18 Supply 380V/3/60Hz

Rated power supply 440V 10%, 3 --- ph, 60Hz

ASK 27 ASK 32
Pre---fuse [A] 35 50
Supply line [mm2] 4x6 4x10
Consumption [A] 30 36
Tab. 19 Supply 440V/3/60Hz

Rated power supply 460V 10%, 3 --- ph, 60Hz

ASK 27 ASK 32
Pre---fuse [A] 35 50
Supply line [mm2] 4x6 4x10
Consumption [A] 22 35
Tab. 20 Supply 460V/3/60Hz

2 --- 7
 Technical Specification

2.10 Refrigeration Dryer

Model

ASK 27 ASK 32
Model *
* Transfer data from dryer nameplate to the table
Tab. 21 Refrigeration dryer models:

Compressed Air System

ABT 27 ABT 32
Pressure drop [bar] 0,2 0,2
(in relation to 7 bar working pressure)
Maximum permitted working pres- 16 16
sure [bar]
Tab. 22 Refrigeration dryer, compressed air system

Refrigeration System

ABT 27 ABT 32
Refrigerant R 134a R 134a
Maximum charge [kg] 0,7 0,9
Maximum permitted working pres- 21 21
sure [bar]
Safety pressure switch set point 21 21
[bar]
Tab. 23 Refrigeration dryer, refrigeration system

2 --- 8
 Safety and Responsibility

3 Safety and Responsibility

Disregarding this notice can result in serious injury!

The machine is made to the latest technical safety standards and acknowledged safety
regulations. Nevertheless, risk of injury and death for the user and third parties and dam-
age to the machine and other property can arise from its use.
The machine may only be used: when it is in 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. The responsibility, in case, lies solely with the 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.

3.2 Incorrect Use

Untreated compressed air may not be used:
as breathing air,
for any process in which the air can come into contact with foodstuff.

3.3 User’s Responsibilities

Personnel
Allow only specialists or persons who have been trained or instructed on this machine to
carry out work on the machine. This applies particularly for:
installation and initial start ---up,
maintenance and service work,
repairs,
inspections.
Allow work to be carried out on electrical equipment only by a qualified electrician or
trained personnel under the supervision of a qualified electrician, and according to electri-
cal engineering regulations.
Ensure that all persons working on the machine have read, understood and observe the
safety ---relevant passages in the service manual.
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 schedules and accident prevention regulations
The machine is subject to local inspection schedules.

3 --- 9
 Safety and Responsibility

Operation in Germany:
Recurring inspections in accordance with VBG 16 --- § 18
The company (user) must ensure that recurring inspections of safety devices on com-
pressors 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
strictest attention to §15.
Inspection Schedule Inspecting authority
Installation and before initial start ---up Qualified persons
equipping (e.g. KAESER Service)
Internal inspection every 5 years after installation Qualified persons
or the last inspection (e.g. KAESER Service)
Strength test every 10 years after installation Qualified persons
or the last inspection (e.g. KAESER Service)
Tab. 24 Inspection schedule for Germany

3.4 Safety Devices

Do not change, bypass or disable safety devices.
Do not remove or obliterate labels and notices.
Ensure that labels and notices are clearly legible.
More information on safety devices is contained in chapter 4 ’Design and Function’, sec-
tion 4.4 ’Safety Devices’.

3.5 Hazards
Principle: always observe accepted safety regulations
Observe accepted safety regulations and national legislation applicable to all work carried
out on the machine.
Examples of these are directives and national regulations concerning safety and accident
prevention.

3.5.1 Danger of electric shock

Electric shock can kill!

DANGER Touching live electric components can cause serious injury or death.


Isolate all phases from the mains supply.
(switch off the mains isolating device)


Ensure that the power supply cannot be switched on again (lock out).


Check that no voltage is present.


Do not work on electrical components unless 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 --- 10
 Safety and Responsibility

Work on the electrical equipment may only be carried out by a qualified electrician or by
instructed persons under the supervision of a qualified electrician.
Before 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 Danger from rotating parts

Danger from belt drive

Danger of serious injury from rotating belt drive

DANGER Touching the rotating belt drive can result in severe crushing or even loss
of extremities.
Do not open the casing while the machine is switched on.
Isolate all phases from the mains supply.
(switch off the mains isolating device)
Ensure that the power supply cannot be switched on again (lock out).
Work carefully.
Danger from fanwheel

Danger of serious injury from rotating fanwheel

DANGER Touching a rotating fanwheel can result in serious injury or even loss of ex-
tremities.
Do not open the casing while the machine is switched on.
Isolate all phases from the mains supply.
(switch off the mains isolating device)
Ensure that the power supply cannot be switched on again (lock out).
Work carefully.

3.5.3 Hazards from compressed air

Hazards from compressed air quality
The compressed air from this machine may not be used without taking appropriate precau-
tions:


as breathing air


for processing foodstuffs

Unsuitably treated compressed air can cause injury or death.

DANGER Injury and/or poisoning when compressed air is inhaled.

Poisoning of foodstuffs when they are processed using unsuitable com-
pressed air.
Never inhale compressed air.
Use appropriate systems for compressed air treatment before using
the compressed air from this machine as breathing air and/or for the
processing of foodstuffs.
Use foodstuff---compatible cooling oil a whenever compressed air is to
come into contact with foodstuffs.

3 --- 11
 Safety and Responsibility

Hazards from compressive forces

Compressed air is a contained force. Uncontrolled release of this force can cause serious
injury or death.

Serious injury or death from released compressive forces.

WARNING
Serious injury or death can result from loosening or opening components
under pressure.
Close shut ---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the ma-
chine.

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 modification of the compressed air supply system

If a compressed air installation is extended or modified check the blow ---off capacity of the
pressure relief valves on air receivers and pipelines before installing the new machines.
Pressure relief valves of insufficient blowoff capacity must be replaced by valves with a
higher capacity.

3.5.4 Hazards from spring forces

Springs under tension represent contained energy. Uncontrolled release of this force can
cause serious injury or death.

There is considerable danger of injury or death from the release of

spring force if spring--- loaded components are incorrectly opened.
WARNING
Minimum pressure/check valves, pressure relief valves and inlet valves are
heavily spring loaded.
Do not open or dismantle valves.

3.5.5 Further dangers

Handling cooling and lubricating fluids

Avoid contact with skin and eyes.


Do not inhale oil mist or vapour.


Do not eat or drink while handling cooling and lubricating 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 parts of the machine or any oil vapours can ignite because of sparks or heat.

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

3 --- 12
 Safety and Responsibility

3.6 Warning Symbols

Beware of life---threatening electrical voltage.
Do not touch electrical components; danger of electric shock.
Before opening, switch off at the main switch and lock off to secure against
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 can start automatically or by remote start command.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.
Beware of rotating fanwheel
Do not open the casing while the machine is switched on.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.
Beware of rotating belt drive
Do not open the casing while the machine is switched on.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.

3.7 Emergencies

3.7.1 Fire fighting

Suitable extinguishing media:


foam


powder


carbon dioxide


sand or earth
Unsuitable or unsafe extinguishing media:


powerful water jet

3.7.2 Cooling oil

Skin contact:
wash off immediately
Eye contact:
rinse thoroughly with lukewarm water and seek medical assistance.
If necessary, request a copy of the safety data sheet for KAESER SIGMA FLUID.

3.7.3 Refrigerant
Inhalation:
Remove the affected person to fresh air and keep them calm.
If breathing stops, apply artificial respiration and call for medical assistance.

3 --- 13
 Safety and Responsibility

Skin contact:
Wash immediately with plenty of water.
Treat burns and frostbite.

Eye contact:
Rinse eye thoroughly with lukewarm water and seek medical assistance.
If required, request a copy of the safety data sheet dealing with the handling of refrigerants
for KAESER dryers.

3.8 Environmental Protection

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 envi-
ronment protection regulations. Observe national regulations. This applies particularly to
parts contaminated with cooling oil.

Do not allow refrigerant to escape into the atmosphere.

Give refrigerant only to authorised bodies for disposal.

3 --- 14
 Design and Function

4 Design and Function

4.1 Machine Overview

4.1.1 Cabinet

Fig. 1 Cabinet

1 Control cabinet door

2 Latch
3 Removable panel
4 Oil level indicator viewing window
5 Condensate drain viewing window
The cabinet, when closed, 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.

4.1.2 Function
Items in brackets [ ] correspond to the Pipe and Instrument Flow Diagram (P & I Diagram)
in chapter 13.2.1.
An air ---cooled machine serves to illustrate function.

4 --- 15
 Design and Function

Fig. 2 Machine

1 Inlet valve [2] 6 Control cabinet

3 Compressor motor [3] 7 Oil separator tank [6]
4 Oil filter [10] 8 Air filter [1]
5 Airend [4] 9 Oil/air cooler [11/13]
10 Refrigeration dryer
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 compressed air in the oil 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 mini-
mum pressure/check valve into the aftercooler (9). The minimum pressure/check valve en-
sures there is always sufficient air pressure to maintain cooling oil circulation.
The aftercooler brings down the compressed air temperature to 5 to 10 K above ambient.
Most of the moisture carried in the air is removed in the aftercooler.

4 --- 16
 Design and Function

Refrigeration Dryer

Fig. 3 Refrigeration dryer and condensate drain

10 Refrigeration Dryer
12 Condensate drain
The downstream refrigeration dryer (10) removes the remaining moisture from the air.
The condensate drain (12) removes the precipitate.

4 --- 17
 Design and Function

4.2 Options

4.2.1 Machine mountings (option H1)

The machine mountings enable the machine to be anchored to the floor.

Fig. 4 Machine mountings

4.3 Operating States and Control Modes

4.3.1 Operating states

There are three operating states:
LOAD: the inlet valve is open. The airend delivers compressed air to the system.
The compressor 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 compressor motor runs without load and draws little current.
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 compresor 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 re-
sponse and in proportion to the air demand. The airend delivers compressed air to the
system.
The load and power consumption of the drive motor rises and falls with the air de-
mand.
The regulating valve is factory set. Consult with KAESER Service before changing.

4.3.2 Tasks of the Controller

Using the selected control mode, the controller switches the compressor between its vari-
ous operational states in order to compensate for air being drawn of by consumers and
maintain system pressure between the set minimum and maximum values.

4.3.3 Control Modes

SIGMA CONTROL BASIC can only work with the following control modes:
DUAL
DUAL
In the DUAL control mode, the compressor is switched back and forth between full load
and idle to maintain system pressure between the set minimum and maximum values.
When the maximum pressure is reached the machine switches to idle running. When the
preset idling time has elapsed the machine is STOPPED.
The idling time is fixed in SIGMA CONTROL BASIC.

4 --- 18
 Design and Function

4.3.4 Modulating control (option C1)

The modulating control mode is an extension of DUAL control. The difference being that, in
this mode, the delivery of the compressor is steplessly varied within the control 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.

4.3.5 Refrigeration dryer control modes

The following control modes are available:
CONTINUOUS
TIMER

CONTINUOUS
In this mode the refrigeration dryer runs continuously, even if the compressor is shut down.
This mode of control is set up at the factory.

TIMER
The refrigeration dryer is time---controlled and is switched on and off when the compressor
is stopped. In this mode, the operating temperature is held within tight limits.
This control mode saves energy.

Which control mode is the most practical, and when?

Control mode Advantage Disadvantage

CONTINUOUS Constant dew point. Higher power consumption
when the compressor is
shut down
TIMER Lower power consumption Brief increase in dew point
when the compressor is when the compressor re---
shut down starts

4.4 Safety Devices

The following safety devices are provided and may not be changed:
EMERGENCY STOP button
The EMERGENCY STOP button shuts down the compressor immediately. 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.
Protection from accidental contact.

4 --- 19
 Design and Function

4.5 Keys and Indicators

Fig. 5 Keys

Symbol Item Description Function

1 ON (I) Switch the machine on.

2 OFF (0) Switch the machine off.

Acknowledges alarm messages and resets event
memory.
6 Arrow key Scrolls down parameter list.
Reduces a parameter value.
7 Arrow key Scrolls up the parameter list.
Increases a parameter value.
8 Escape Exits the edit mode without saving.

9 Return/enter/save Only affects the message in the third line of the dis-
key play (12).
Jumps to the edit mode.
Saves and leaves the edit mode.
Tab. 25 Buttons

4 --- 20
 Design and Function

Fig. 6 Indicators

Symbol Item Description Function

12 Display field (Dis- Alphanumeric display with 4 lines.

play)
13 Alarm Blinks red when an alarm occurs.
Lights continuously when acknowledged.
15 Service/warning Lights continuously yellow for:
LED --- maintenance work required
--- warning message
16 Controller voltage Lights green when the power supply to the controller
is switched on.
19 Machine ON Lights green when the machine is switched on.

Tab. 26 Displays

4.6 Function Description

4.6.1 Display field layout (Display, Position 12, Fig. 6)

Line 1 x x . x b a r
Line 2 y y ˚ C
Line 3 z 0 0 0 0 h
Line 4 1 2 3 4 5 6 7 8 S p T i

Fig. 7 Display layout (Display)

Line Display Meaning

1 XX.X Current system pressure in bar, psi or MPa.
2 yy Current airend discharge temperature (ADT) in ˚ C or ˚ F.
3 0...9 Parameter display and setting (see Tab. 28)
4 1,2... Alarm and warning messages (see Tab. 29 and Tab. 30)
Tab. 27 Display field (Display)

4 --- 21
 Design and Function

4.6.2 Display of Parameters

Line Display Meaning

3 0 Operating hours counter
Displays the period in which the motor was switched on.
1 Load hours counter
This shows the number of hours the compressor has operated
under load.
2 Maintenance interval counter
Displays the number of operating hours until the next scheduled
maintenance.
It counts back from a set value. The warning message ”S” is dis-
played when the counter reaches zero.
When maintenance is complete the counter should be reset to its
original value. The interval begins to run out again.
3 Pressure relief valve check mode on/off (password protected)
This switches the pressure relief valve blowoff pressure check on
and off.
The warning message ”i” is displayed when the check mode is
switched on.
Checking and finding password: see chapter 10.8.
4 Temperature display units
The airend discharge temperature can be displayed in ˚ C or ˚ F.
5 Pressure display units
Current working pressure can be displayed in bar, psi or MPa.
6 Activate refrigeration dryer: on/off
In this operating mode the integrated refrigeration dryer operates
(if provided).
on: Impulse timer
off: Continuous
7 System pressure: Switching differential
The switching differential is the difference between cut ---in pres-
sure and cut ---out pressure (required system pressure) and deter-
mines the frequency of switching between LOAD and IDLE RUN-
NING.
Setting range: ---0.1...---5.0 bar
8 Required system pressure: switching point
The the switching point is the required pressure of the air main
(system pressure) and the cut ---out pressure of the compressor.
Setting range (bar): 5.5...maximum system pressure
9 Maximum working pressure
The compressor can deliver air up to this pressure (see name-
plate).
The maximum working pressure is factory ---set and can only be
changed by authorized KAESER service
Tab. 28 Parameters

4 --- 22
 Design and Function

4.6.3 Parameter setting

The edit mode can be entered by depressing the ”Enter” key for three seconds.
If a password is needed it is requested automatically.
Every action may be retracted by means of the escape key (esc).

If no key is pressed in the edit mode for ten seconds the display automati-
cally returns to the previous mode.

Restarting the controller is not necessary. Edited parameters are immedi-

ately effective.

System pressure and airend discharge temperature are neither updated

nor displayed whilst in the edit mode.

Scroll with the arrow keys until the desired parameter appears in line 3.
Depress the enter key for at least three seconds.

Without password protection

The current parameter setting blinks.
Use the arrow keys to change the setting and confirm with the enter key.

With password protection

The password consists of five characters. The first character blinks.
Use the arrow keys to change the setting and confirm with the enter key.
The next character blinks.
Repeat setting until all characters are entered.
When the correct password is entered the parameters are displayed.
Use the arrow keys to change the setting and confirm with the enter key.

4 --- 23
 Design and Function

4.6.4 Alarm and warning message recognition

A complete list with instructions on fault rectification is given in chapter 9.

Alarm messages (machine shuts down)

Line Display Symbol Meaning

4 1 Safety chain
EMERGENCY STOP button pressed.
Access door open (if provided).
2 Motor fault
Overload protection of drive or fan motor (if pro-
vided).
3 Back pressure present.
Incorrect motor rotation direction.
--- Drive belt broken
--- Compressor not vented on standstill.
4 Maximum permissible airend discharge temperature
exceeded.

5 Fault in the refrigeration dryer.

6 Defective analog input (pressure or temperature sen-

sor).

7 Maximum permissible temperature of the controller

exceeded.

8 Reserve
Tab. 29 Alarms

Warning messages (machine does not shut down)

Line Display Symbol Meaning

4 S Maintenance interval elapsed.

p Back pressure present.

T Machine below minimum permissible starting tem-

perature.

i Pressure relief valve check modus switched on.

Tab. 30 Warning messages

4 --- 24
 Installation and Operating Conditions

5 Installation and Operating Conditions

5.1 Ambient Conditions

There must be no open flames or sparks at the place of installation.
Any welding work carried out on the equipment must not cause a fire 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.
For instance, the requirements of 94/9/EC (ATEX directive) for correct use in explosion
hazardous 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 Installation Conditions

5.2.1 Place of installation and space required

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

Fig. 8 Installation recommendation, dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Inlet air opening

5 --- 25
 Installation and Operating Conditions

5.2.2 Ventilation
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
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.

ASK 27 ASK 32
Inlet opening [m
] 0,5 0,6
Extractor for forced venti- 7500 8500
lating:
Flow rate [m  /h] at 100 Pa
Exhaust air duct: 350 x 650 350 x 650
Dimensions [mm]
Tab. 31 Ventilation

Exhaust ducting
Consult the manufacturer on the design of the ducting, length, number of bends, etc.
Further information on exhaust air ducts can be found in chapter 13.2.3.

5.2.3 Operating in a compressed air network

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.
KAESER is ready to offer good advice.

5 --- 26
 Installation

6 Installation

6.1 Safety

There is considerable danger of injury or death if insufficiently or inad-

equately treated compressed air is used.
DANGER
Injury and/or poisoning caused by the use of insufficiently treated com-
pressed air as breathing air or for the processing of foodstuffs.
Never use compressed air as breathing air unless it has been suitably
treated, the pressure is appropriately reduced and breathing appar-
atus 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--- loaded components are incorrectly opened (dis-
WARNING mantled).

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 may only be carried out by persons fully conversant with the basic safety con-
cepts of compressed air engineering.

6.2 Report any Transport Damage

Check the machine for visible and hidden transport damage.
Inform the carrier and the manufacturer in writing of any damage.

6.3 Install the Compressed Air Connection

Pre --- condition: air main completely vented.

Fig. 9 Compressed Air Connection

1 Axial compensator or flexible hose
2 Shut ---off valve

6 --- 27
 Installation

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 compensa-
tor (1).

6.4 Electrical Connection

Have the electrical connection made only by a qualified and authorised electrician.
Carry out protection measures as stipulated in relevant regulations (IEC 364 or DIN
VDE 0100, for example) and in national accident prevention regulations (BGV A2 in Ger-
many). Also observe the regulations of the local power utility company.

Use wire conductor dimensions and fuse ratings in accordance with local 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 2.9.

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

Before Initial Start--- up

The control transformer in the control cabinet has connections for various supply volt-
ages. Check that the correct connections are made for the supply voltage provided for
the machine. If necessary, re---connect the transformer the match the supply voltage.
(see Fig. 10 and chapter 13.2.4)

1 1 3

1 1 3

Fig. 10 Control Transformer Connection

1 Primary
2 Secondary
3 Mains supply

6 --- 28
 Installation

Connect the machine to the mains power supply in accordance with Fig. 11 and the
electrical diagram in chapter 13.2.4.

Fig. 11 Electrical Connection

1 User ---provided main switch and fusing

6.5 Condensate Drainage Connection

A hose connection is provided for condensate drainage. Condensate must drain freely.

Collect condensate in a suitable container and dispose of in accordance

with environmental regulations.

Condensate drainage connection

Fig. 12 Condensate drainage, dimensions [mm]

1 Drain hose
2 Condensate collecting line

6.6 Options

6.6.1 Machine fixing (option H1)

If the machine is supplied with mountings, these can be used to anchor it to the floor. De-
tails of the fixing holes are contained in the dimensional drawing in chapter 13.2.3.
Use appropriate bolts to anchor the machine.

6 --- 29
 Initial Start--- up

7 Initial Start---up

7.1 Before Initial Start---up (or Recommissioning)

A trained specialist may only carry out the initial start ---up procedure.
Incorrect start ---up can cause damage to the machine.
Special measures on recommissioning after storage

Storage period longer Action

than
12 months Change the oil filter.
Change the oil separator cartridge.
Change the cooling oil.
Have the motor bearings checked by an authorised
KAESER service agent.
36 months Have the overall technical condition checked by an autho-
rised KAESER service agent.

7.2 Check installation and operating conditions

Cover all points in the check list before starting the machine.

To be checked Chapter Done?

1 Are all conditions for installation in order? 5
2 User’s lockable supply disconnecting device installed? 6.4
3 Is the power supply as specified on the nameplate? 2
4 Supply cable section and fuse rating adequate? 2.9.2
5 All electrical connections checked for tightness?
6 Shut ---off valve fitted to compressed air outlet? 6.3
7 Connection made to air main with hose or axial compen- 6.3
sator?
8 Belt tension checked? 10.7
9 Is there sufficient cooling oil in the separator tank?
(cooling oil indicator outside the red zone?)
10 Required quantity of cooling oil poured into the inlet port? 7.4
11 Are the operators full conversant with safety regulations?
12 Machine anchored to the floor? 6.6.1
(option H1)
13 Are all access doors closed and latched and all removable 4.1.1
panels in place and secured?
Tab. 32 Checklist, installation conditions

7.3 Setting the overload protection cut---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 machine current (see nameplate in the con-
trol cabinet).
Setting

7 --- 30
 Initial Start--- up

The standard setting is made at the factory.

To prevent the overload protection cutout from being triggered by voltage fluctuations, tem-
perature influences or component tolerances, the setting can be up to 15% higher than the
arithmetical phase current.

7.4 Pour cooling oil into the inlet port

Material: 0.5 l cooling oil

Pre --- condition: Machine switched off.

Mains disconnect locked out.

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 type of oil.

A sticker giving the type of oil used is found near the oil separator tank filling port.

Fig. 13 Inlet valve oil filling port

1 Screw plug
2 Inlet valve
Remove the plug (1) from the inlet valve (2).
Pour oil into the inlet valve and replace the screw plug.
Turn the rotors over by hand by means of the belt pulley to distribute the oil.

7.5 Checking Direction of Rotation

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.

Switch the machine off as soon as the direction of rotation is seen

and compare it with the direction arrows on the motor and airend.

7.6 Initial Start---up

Open the shut ---off valve to the air network.

7 --- 31
 Initial Start--- up

Switch on at the main supply isolator.

The controller makes a self---test and the green LED ’Control voltage ON’ lights.
Press the ’ON’ key.
The green LED ’Machine ON’ lights.
The motor runs up and after a short time the machine switches to LOAD and deliveres
compressed air.

Watch for any faults occurring in the first hour of operation.

After the first 50 operating hours carry out the following:

Check that all electrical connections are tight.

Check belt tension.

7.7 Setting System Pressure

The cut ---out pressure is factory set at the maximum working pressure of the machine.
Adhustment is necessary for individual operating conditions. (paramente 8 ”System pres-
sure: switching point”)

The cut ---out pressure may not be set above the maximum working pres-
sure of the connected air network.

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.
(paramente 7 ”System pressure: switching differential”)
Add an air receiver downstream to increase buffer capacity.

System pressure: switching point

Scroll with the arrow keys until the parameter 8 ”System pressure: switching point” is
displayed in line 3.
Depress the enter key for at least three seconds until the cursor blinks.
Use the arrow keys to set the desired switching point and confirm with the enter key.

System pressure: switching differential

This switching differential is factory set. Adjust parameter for too frequent switching.
Scroll with the arrow keys until the parameter 7 ”System pressure: switching differen-
tial” is displayed in line 3.
Depress the enter key for at least three seconds until the cursor blinks.
Use the arrow keys to set the desired switching differential and confirm with the enter
key.

7 --- 32
 Operation

8 Operation

Fig. 14 Switching On and Off

1 ’Machine ON’ LED (green) 3 OFF key (’0’)

2 ’ON’ key (’I’) 8 ’Power ON’ LED (green)

8.1 Switching On and Off

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

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.

Damage from machine under--- temperature.

CAUTION Frozen condensaet and viscous cooling oil can result in damage when
starting the machine.
Make sure the temperature of the machine is at least + 3 ˚ C before
starting.
Heat the compressor room or install an axuliary heater in the com-
pressor.

8.1.1 Switching on
Switch on at the main supply isolator.
The controller makes a self---test and the green LED ’Power ON’ (8) lights.
Press the ’ON’ key (2).
The green LED ’Machine ON’ lights (1).
The compressor motor runs as soon as the network pressure is lower than the cut ---out
pressure.

8 --- 33
 Operation

8.1.2 Automatic restart

Pre --- condition: System pressure is lower than cut ---out pressure.

The machine can restart automatically when power is resumed after a power cut.

8.1.3 Switching off

Press the ’OFF’ key (3).
The ’Machine ON’ LED goes out (1).
Switch off and lock out the main supply isolator.

8.2 Switching Off in an Emergency and Switching On Again

Fig. 15 Switching off in an emergency

9 EMERGENCY STOP button

Switching off
Press the ’EMERGENCY STOP’ button (9)
The ’EMERGENCY STOP’ remains latched in.
The machine pressure system is vented and the machine is prevented from re---starting.

Starting again

Pre --- condition: Rectify fault.

Turn the ’EMERGENCY STOP’ button in the direction of the arrow to unlatch it.
Press the ’Reset’ key to delete and existing alarm messages.
Switch the machine on.

8 --- 34
 Operation

8.3 Acknowledging and Resetting Warning and Alarm Messages

Fig. 16 Acknowledging and Resetting Warning and Alarm Messages

10 ’Warning’ LED (yellow)
11 ’Alarm’ LED (red)
12 ’Acknowledge’ (reset) key

Alarm
An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11).
Faults are displayed on the ”New value” principle:
The alarm is triggered LED blinks
Alarm is acknowledged LED illuminates
Alarm delets LED out
or
The alarm is triggered LED blinks
Alarm delets LED blinks
Alarm is acknowledged LED out

Warning
The countdown of the service interval counter is displayed.
The warning LED (yellow) illuminates (10).

8.3.1 Resetting alarm messages

Pre --- condition: Fault rectified.

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

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

8.4 Shutting Down the Refrigeration Dryer (option T3)

If the compressor is to be run without the refrigeration dryer, the dryer can be shut down
by means of its motor protection switch (refrigerant compressor motor).
The motor protection switch is located in the control cabinet. It is marked ---Q13 on the
electrical diagram (see allocation plan in chapter 13.2.4).
Shut down the refrigeration dryer by means of its motor protection switch ( ---Q13).

8 --- 35
 Event Recognition and Fault Rectification

9 Fault Recognition and Rectification

Inform KAESER service if the fault cannot be rectified by the action suggested.
Do not attempt rectification measures other than those given in this manual.
The messages valid for your machine are dependant on the controller and individual
equipment.
There are three types of fault:

Description Indicated by see chapter

Alarm blinking red LED 9.1
(with automatic
shut ---down)
Warning yellow LED illuminates 9.2
(no shut ---down)
Miscellaneous faults no indication 9.3

9.1 Alarm messages on the controller (machine off)

Message Possible cause Action to take KAESER service

technician only
1 EMERGENCY STOP Unlatch the push-
button pressed. button.
Access door open. Close access door.
2 Motor fault Check overload
Shutdown after over- protection setting /
load motor protection
switch.
Change oil separ-
ator cartridge.
Check minimum
pressure/check
valve.
Investigate cause.
3 The motor is turning Changeover phase
in the wrong direc- lines L1 and L2.
tion.
Drive belt broken Replace drive belt.
4 Maximum airend Clean the cooler.
discharge tempera- Cooling air outlet too
ture exceeded. near a wall
Check the cooling
oil level.
Ensure permitted
room temperature
not exceeded.
Check the cooling
oil level.
Replace the oil filter.

9 --- 36
 Event Recognition and Fault Rectification

Message Possible cause Action to take KAESER service

technician only
5 Fault in the refriger- Clean the refrigerant Have refrigeration
ation dryer. condenser. dryer checked.
Ensure adequate
ventilation.
Install an extractor.
Clean the cooler.
6 Broken wire, earth Check line and con-
or short circuit on nection.
analog input
7 Maximum permiss- Ensure adequate
ible temperature of ventilation.
the SIGMA CON- Ensure permitted
TROL BASIC hous- room temperature
ing exceeded. not exceeded.
8 ---
Tab. 33 SIGMA CONTROL BASIC alarm messages and Rectification Measures

9.2 Warning messages on the controller (yellow LED illuminated)

Message Possible cause Action to take KAESER service
technician only
S Maintenance Carry out mainten-
necessary. ance.
p Compressed air Have machine
flows back into the checked.
machine.
T Machine to cold for
Increase room tem- Install auxiliary heat-
starting. perature. ing.
i Pressure relief valve
Check pressure re-
check modus lief valve.
switched on. Deactivate check
mode.
Tab. 34 SIGMA CONTROL BASIC alarm messages and Rectification Measures

9 --- 37
 Event Recognition and Fault Rectification

9.3 Miscellaneous faults

Alarm Possible cause Action to take KAESER service
technician only
Machine runs but Inlet valve not open- Check the inlet
produces no com- ing or only opening valve.
pressed air. partially.
Check the control
valve
Venting valve not Check venting valve.
closing. Check the control
valve
Pressure system Check pipework and
leaking. connections for
leaks and tighten.
The air demand is Check air network Install auxiliary com-
greater than the ca- for leaks. pressor.
pacity of the com-
Shut down the con-
pressor. sumer(s).
Hose coupling or Remove coupling or
maintenance hose maintenance hose.
still plugged into the
quick ---release
coupling on the oil
separator tank.
Cooling oil runs out Oil level in the sep- Drain off oil until the
of the air filter. arator tank too high. correct level is re-
ached.
Inlet valve defective Check the valve.
Compressor Air receiver too Install an air receiver
switches between small. of sufficient capacity.
load and idle more Flow into the air net- Increase air line di-
than twice per min- work restricted. ameters.
ute.
Check filter el-
ements.
Switching differential Check switching dif-
between cut ---in and ferential.
cut ---out pressure
too is small.
Oil leaking into the Hose coupling or Remove coupling or
floor pan. maintenance hose maintenance hose.
still plugged into the
quick ---release
coupling on the oil
separator tank.
Oil cooler leaking Replace the oil
cooler.
Connection leaking. Tighten connec-
tions.
Replace seals.

9 --- 38
 Event Recognition and Fault Rectification

Alarm Possible cause Action to take KAESER service

technician only
Cooling oil con- Unsuitable oil used. Use SIGMA FLUID
sumption too high. cooling oil.
Oil separator car- Change oil separ-
tridge split. ator cartridge.
Oil level in the sep- Drain off oil until the
arator tank too high. correct level is re-
ached.
Oil return line Check dirt trap in
clogged. the oil return line.
Tab. 35 Miscellaneous events (faults)

9 --- 39
 Maintenance

10 Maintenance

10.1 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 completely from the mains supply (all conductors)
(switch off at the main isolator)
Ensure the supply cannot be switched on 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.

There is considerable danger of injury or death from the release of

spring force if spring--- loaded components are incorrectly opened (dis-
WARNING mantled).

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 injury or death can result from loosening or opening components
under pressure.
Close shut ---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the ma-
chine.
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 or complete breakdown can result.
Test run after maintenance or service.
Carry out a visual check of the machine.

10 --- 40
 Maintenance

Maintenance work may only be carried out:

by persons trained in the machine and persons under the supervi-

sion of an expert,
by experts,
by an authorised KAESER service agent.

Work on electrical devices may only be carried out in accordance with elec-
trical regulations:

by persons trained in the machine under the supervision of an

electrician,
by an electrician,
by an authorised KAESER service agent.

10.2 Maintenance Schedule

Maintenance intervals are recommendations only and should be adjusted

to suit the installation and operating conditions.

The counting down of the maintenance interval indicator shows when the next mainten-
ance action is due.


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 Resetting maintenance interval counters

Maintenance interval counters indicate the operating hours between maintenance tasks.
When a maintenance task is completed, reset the corresponding counter to its original
value.


Scroll with the arrow keys to select parameter 2 ”Maintenance interval counter”.


Depress the enter key for at least three seconds.


When the cursor blinks, confirm the offered value with the enter key.

10 --- 41
 Maintenance

10.2.2 Regular Maintenance Tasks

When operating conditions are unfavourable (e.g. dusty atmosphere) or

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

Pay attention to the controller’s service messages.

Interval Maintenance tasks see chapter

weekly Check cooling oil level. 10.10.1
Clean or renew the filter mats. 10.3 / 10.4
every 500 hours Check and re---tension drive belts. 10.7
every 1,000 hours Oil and air cooler maintenance. 10.3
Clean the refrigerant condenser. 10.14.1
up to 3000 hours Air filter maintenance. 10.5
up to 3000 hours Change oil separator cartridge. 10.13
at least every 3
years
up to 6000 hours Change the oil filter. 10.12
at least annually
up to 12,000 hours Change the drive belts 10.7.2
at least every 3
years
variable (see Change the cooling oil. 10.11
table 37)
annually Check all electrical connections.
Check the pressure relief valve. 10.8
Check the oil and air coolers for leaks. 10.3
Clean the condensate drain. 10.14.3
h = operating hours
Tab. 36 Regular maintenance tasks

10 --- 42
 Maintenance

10.2.3 Cooling oil changing intervals

Please observe national regulations regarding the use of cooling oil in oil---injected
screw compressors.
Machine duty cycle and ambient conditions are important criteria for the number and
length of the change intervals.

KAESER Service will support you in determining appropriate intervals and

provide information on the possibilities of oil analysis.

Check operating conditions and adjust intervals as necessary; keep results in a

table 37for future reference.

Cooling oil Maximum permissible oil change interval

[operating hours / year]
Favourable operat- Unfavourable oper- My operating condi-
ing conditions* ating conditions tions
SIGMA FLUID PLUS / 6 000* * / 2 3 000 / 1
S---460
SIGMA FLUID MOL 3 000 / 1 2 000 / 1
SIGMA FLUID FGL 3 000 / 1 2 000 / 1
SIGMA FLUID FGH 3 000 / 1 2 000 / 1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
* * Changing intervals > 6000 operating hours, permissible only with oil analysis.
Tab. 37 Cooling oil changing intervals

10.2.4 Regular Service Work

Only authorised KAESER 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 at
more intervals.

Interval Service work

up to 12,000 hours Check valves.
Up to 12,000 hours, Change the drive motor bearings.
at the latest every 3
years
Up to 36,000 hours, Change the hose lines.
at the latest every 8
years
Tab. 38 Regular service work intervals

10 --- 43
 Maintenance

10.3 Cooler Maintenance

Material: Warm water and household detergent
Spare parts (as required)
Brush
Vacuum cleaner

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is cooled down.

Check the cooler regularly for contamination. Frequency is mainly dependant on local op-
erating conditions.
Contamination causes overheating and machine damage.

A filter mat protects the aftercooler and oil cooler from contamination.

Fig. 17 Cooler filter mats

1 Filter mat
Removing the filter mat
No tools are needed to remove the filter mat.
Carefully remove the filter mat (1) from the retaining frame.
Cleaning the filter mat
Gently beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary,
wash with lukewarm water and household detergent.
Renew the mat if cleaning is not possible of has already been carried out
five times.

Cleaning the cooler

Avoid dust disturbance. Wear breathing apparatus if necessary.
Do not use sharp objects to clean the cooler. The cooler could be damaged.
A severely contaminated cooler should be cleaned by a KAESER service agent.
Dry brush the cooler and use a vacuum cleaner to suck up the dirt.
Replacing the filter mat
Carefully insert the filter mat (1) in the retaining frame.

10 --- 44
 Maintenance

10.4 Filter mat maintenance (control cabinet)

Material: Warm water and household detergent

Spare parts (as required)

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is cooled down.

Fig. 18 Control cabinet ventilation grill

1 Ventilation grill
2 Filter mat
Removal
Carefully remove the ventilation grill (1) and the filter mat (2).

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

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

10.5 Maintain the Air Filter.

Material: Spare parts

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is cooled down.

10 --- 45
 Maintenance

Fig. 19 Air filter maintenance.

1 Retaining clip
2 Air filter element
3 Casing
Do not clean the air filter element.

All sealing surfaces are matched to each other.

The use of unsuitable air filter element can permit dirt to ingress into the
pressure system and cause damage to the machine.

Detach the air filter housing:

Release the casing retaining clips (1), detach the casing (3) and and lift out the filter
element (2).
Replace the filter casing:
Clean all parts and sealing surfaces.
Insert the new filter element (2) in the casing (3).
Attach the casing (3) with the retaining clips (1) to the inlet valve.
Close all access doors and replace all cover panels.
Switch on the power supply and reset the maintenance interval counter.

10.6 Electric Motor Maintenance

Compressor motor
The bearings of the compressor motor are permanently greased.

10.7 Maintain the Drive Belts

10.7.1 Check the belts and their tension.
Pre --- condition: Machine switched off.
Mains disconnect locked out.
Machine is cooled down.

Check the belts after the first 24 ---hours of operation.

10 --- 46
 Maintenance

2
1

1 Nut
2 Nut
3 Marker pin

Check for damage

Change any damaged belts immediately.

Turn the pulley by hand so that all of the belt van be inspected for damage.

Check belt tension and adjust if necessary.

The automatic tensioner uses spring force to apply correct tension to the belts.
Adjustment must be made when the marker pin (3) reaches the top of the elongated hole.
Loosen the locking nut (2).
Use the adhusting nut (1) to adjust spring tension until the marker pin (3) reaches the
lower end of the elongated hole.
Retighten the locking nut (2).

10.7.2 Changing the belts

Loosen the locking nut (2).
Turn adjusting nut (1) to loosen the tension on the belts until they can be removed
from the pulley.
Install the new set of belts and use the adhusting nut (1) to adjust tension until the
marker pin (3) reaches the lower end of the elongated hole.
Retighten the locking nut (2).
Check tension after the new belts have been in operation for 24 ---hours.

10.8 Check the Pressure Relief Valve.

Pre --- condition: Machine switched off.

In order to check the pressure relief valve, the machine’s working pressure is raised above
the blowoff pressure of the valve.

10 --- 47
 Maintenance

Exceeding the permissible working pressure can result in a loud

knocking noise and the danger of bursting.
WARNING

Excessive noise is caused when the pressure relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and 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 blow ---off
pressure of the valve.

Blow ---off protection and system pressure monitoring are switched off dur-
ing the test.
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.
Read the blow ---off pressure on the valve. (the blow ---off pressure is usually to be
found at the end of the part identification)
Use the arrow keys to scroll the parameter 3 ”Pressure relief valve check mode” and
confirm by depressing the enter key at least three seconds.
Enter the password ”BASIC” and confirm with the enter key.
Use the arrow keys to select parameter ”on” and confirm with the enter key.
Press the ’ON’ key (1) briefly.
Tha machine starts in IDLE. When the ON (I) key is pressed and held the machine
switches to LOAD and pressure builds up in the oil separator tank.
When the ON (I) key is released the machine switches back to IDLE running and stops
automatically when the set idling period has elapsed.
Observe the pressure indicator on the SIGMA CONTROL BASIC while depressing the
ON (I) key.
Stop the test as soon as the pressure relief valve blows off or working pressure re-
aches 10% above the blowoff set point.
If necessary, vent the machine and replace the pressure relief valve.
Call up the edit mode again and enter the password ”BASIC”.
Use the arrow keys to select parameter ”off” and confirm with the enter key.
Open the user’s shut ---off valve between the machine and the air main.

10.9 Vent the Machine Manually

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is cooled down.

10 --- 48
 Maintenance

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.

Fig. 20 Ventilate the machine.

1 Hose coupling (air cooler venting) 6 Male hose coupling/fitting
2 Pressure gauge 7 Shut ---off valve
A: closed
B: open
3 Hose coupling (oil separator tank vent- 8 Maintenance hose
ing)

10 --- 49
 Maintenance

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 service.

Manually venting the oil separator tank

With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (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 Check and Top ---up the Cooling Oil

10.10.1 Check cooling oil level.

Pre --- condition: Machine cabinet closed.

The machine has been running at least five minutes under LOAD.

The oil level can be seen through the window in the front inspection door.

Fig. 21 Check cooling oil level.

4 Indicator markings min Minimum oil level

5 Green zone OK Oil level optimum
max Oil level maximum
Read ---off fluid level with machine running.
When the indicator shows minimum level, top up the oil.

10 --- 50
 Maintenance

10.10.2 Topping up the cooling oil

Material: Cooling oil

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is 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.

Fig. 22 Topping up the cooling oil

1 Hose coupling (air cooler venting) 5 Oil level indicator

2 Pressure gauge 6 Male hose coupling/fitting
3 Hose coupling (oil separator tank vent- 7 Shut ---off valve
ing) A: closed
B: open
4 Oil filling port with plug 8 Maintenance hose
Check that the oil separator tank pressure gauge (2) reads zero.

10 --- 51
 Maintenance

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 service.

Manually venting the oil separator tank

With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (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 coupl-
ing (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

Replace and lock all cabinet panels and doors.
Open the user’s shut ---off valve between the machine and the air main.
After about ten minutes, check the oil level and top up if necessary.
Switch machine off and check for leaks.

10.11 Change the Cooling Oil

Material: Cooling oil

Oil container

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 re-
gulations.

Danger of burning from hot components and oil.

CAUTION
Wear long ---sleeved clothing and gloves.

Work carefully.

10 --- 52
 Maintenance

Fig. 23 Changing the Cooling Oil, Oil Separator Tank

1 Hose coupling (air cooler venting) 6 Male hose coupling/fitting
2 Pressure gauge 7 Shut ---off valve
A: closed
B: open
3 Hose coupling (oil separator tank vent- 8 Maintenance hose
ing)
4 Oil filling port with plug 9 Hose coupling (oil drain)
5 Oil level indicator 10 Shut ---off valve (venting line)
11 Shut ---off valve (oil drain)
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 if the machine
is not operational
is to be restarted after a long standstill period.
Oil changing with help from internal pressure

Pre --- condition: The machine has been running at least five minutes under LOAD.
Machine is switched off.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.

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 off and lock out the main supply 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: Machine switched off.

Mains disconnect locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
External source of compressed air available.

10 --- 53
 Maintenance

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 service if condensate is 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 coupl-
ing (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 es-
capes.
Close the shut ---off valve (11) and unplug the hose.
Draining the oil from the cooler

Fig. 24 Changing the Cooling Oil

1 Oil cooler 6 Male hose coupling/fitting

2 Hose coupling (oil drain) 7 Shut ---off valve
3 Shut ---off valve
Have the oil container ready.
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (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.

10 --- 54
 Maintenance

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. 23) slowly.
Fill with 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.
Switch on the power supply and reset the maintenance interval counter.
Switch the machine on.
After about five minutes, check the oil level and top up if necessary.
Switch machine off and check for leaks.

10.12 Oil filter maintenance

Material: Spare parts
Oil container

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.

Danger of burning from hot components and oil.

CAUTION
Wear long ---sleeved clothing and gloves.
Work carefully.

Fig. 25 Change the oil filter

1 Oil filter
2 Direction to unscrew

10 --- 55
 Maintenance

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.

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.
Switch the machine on.
After about five minutes, check the oil level and top up if necessary.
Switch machine off and check for leaks.

10.13 Changing the Oil Separator Cartridge

Material: Spare parts
Cleaning rags

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
Machine is cooled down.

The life of the oil separator cartridge is influenced by:

contamination in the air drawn into the compressor,


Compliance with change intervals of


Cooling oil


Oil filter


Air filter

The oil separator element cannot be cleaned.

Dispose of parts and materials contaminated with oil in accordance with

environmental protection regulations.

10 --- 56
 Maintenance

Fig. 26 Changing the oil separator cartridge

14 Cover 19 Nut (self locking)

15 Dirt trap 20 Fitting
16 Air pipe 21 Gasket
17 Retaining screw 23 Oil separator cartridge

Unscrew the fitting (20) and carefully put the parts to one side; pull out the copper
pipe at item (15).
Unscrew the nut (19) and turn the air pipe (16) to one side.
Remove the cover retaining screws (17) and carefully lift the cover (14).
Take out the old oil separator element (23) together with the gaskets (21) and dispose
of according to environmental regulations.
Clean all sealing faces.
Insert the new oil separator cartridge with gaskets and re---fix the cover.
Renew the dirt trap (15) strainer and O ---ring.
Attach the air pipe to the cover with a new, self---locking nut.
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.
After a few minutes of operation, stop the machine and check for leaks.

10 --- 57
 Maintenance

10.14 Refrigeration dryer

Fig. 27 Refrigeration dryer

1 Removable panel
2 Condensate drain viewing window
3 Condensate drain
4 Refrigerant condenser
5 Latch

10.14.1 Cleaning the refrigerant condenser

Material: Compressed air
Vacuum cleaner

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine is cooled down.

Release the latch (5) and take off the panel (1).
Use compressed air (< 5 bar) to blow the condenser (4) through from outside to in-
side and then vacuum up the dirt.
Replace the panel.

10.14.2 Check condensate drainage.

Pre --- condition: Machine running.

Fig. 28 Test condensate drain

1 TEST button

10 --- 58
 Maintenance

The ”Valve” LED lights as soon as condensate begins to drain. This can be
seen through the viewing window (2, Fig. 27).

Condensate drainage can be checked without opening the machine en-

closure.

Manual test
Release the latch (5) and take off the panel (1).
Press and hold the TEST button (1) for at least two seconds.
The condensate drain opens.
Condensate does not drain out?
The drain line (hose) at the back of the drain is blocked.
Switch the machine off and clean or replace the drain hose.
Repeat the test.
Condensate does not drain out?
Condensate drain blocked.
Clean the condensate drain as described in chapter 10.14.3.

10.14.3 Cleaning the condensate drain

Material: Compressed air for blowing out
Cleaning rags
Spare parts (as required)

Pre --- condition: Machine switched off.

Mains disconnect locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
Machine is cooled down.

Fig. 29 Cleaning the condensate drain

1 Screw 7 Fitting
2 Diaphragm 8 Compression spring (valve core)
3 Screw 9 Valve core
4 Diaphragm seat 10 Casing
5 Compression spring (diaphragm) 11 Cap
6 Diaphragm cover

10 --- 59
 Maintenance

Removing the condensate drain

Close the shut ---off valve upstream of the condensate drain.
Unscrew the drain hose fitting (7).
Remove the securing screws (1) and remove the drain.

Cleaning the condensate drain

Unscrew the securing screws (3) and remove the diaphragm seat (4).
Take out and clean the compression springs (5 and 8), the diaphragm (2) and the
valve core (9).
Renew damaged or worn parts.
Blow out the casing with compressed air (< 5 bar).
Reassemble and check correct seating of spring and diaphragm.

Remounting the condensate drain

Re---attach the drain to the shut ---off valve fitting.
Re---connect the drain hose fitting and open the shut ---off valve upstream of the drain.
Close all access doors; replace and secure all removable panels.

10 --- 60
 Maintenance

10.15 Logging Maintenance Work

Machine number:
Date Maintenance task carried out Operating hours Signature

Tab. 39 Maintenance log

10 --- 61
 Spares, Operating Materiels, Service

11 Spares, Operating Materials, Service

11.1 Note the nameplate

Take data from the nameplate for all enquiries and spare parts orders.

11.2 Ordering Maintenance Parts and Operating Materials

Personal injury or machine damage may result from the use of unsuit-
able spare parts or operating materials.
CAUTION
Unsuitable or poor quality maintenance parts and operating materials may
damage the machine or impair its proper function.
Damage to the machine can also result in personal injury.
Use only genuine spare parts and authorised operating materials.

Have an authorised KAESER service agent carry out regular mainten-

ance.
KAESER maintenance parts and operating materials correspond to the original. These are
correct for use in our machines.

Compressor

Name Quantity material number

Air filter element 1 1250
Filter mat (cooler) 1 1050
Control cabinet filter mat 2 1100
Oil filter 1 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Drive belts 1 1800
Tab. 40 Machine maintenance parts

11.3 Maintenance Contract

Sign a maintenance contract with an authorised KAESER service agent.
This ensures the utmost reliability and availability of your compressed air supply system.

11.4 Service Addresses

Address of KAESER agents are given at the end of this manual.

11.5 Spare Parts for Service and Repair

These spare parts lists are intended for trained personnel.
They contain important information for preventive service.

Service and repair work not described in the this manual should only be
carried out by a KAESER service workshop or one authorised by KAESER.

11 --- 62
 De --- commissioning, Storage and Transport

12 De---commissioning, Storage and Transport

12.1 De ---commissioning
De---commissioning is necessary when:
the machine will not be needed for some time,
the machine is to be moved to another location,
the machine is no longer needed,
the machine is to be scrapped.
Temporarily out of service

Pre --- condition: The machine can be started at regular intervals.

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: 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 supply isolator switched off and locked.

Allow the machine to cool down completely.


Disconnect all air and electrical connections.

12.2 Packing
Material: Desiccant
Plastic sheeting
Wooden transport crate

Pre --- condition: Machine is de---commissioned.

Machine dry and cool.

Place desiccant inside the machine cabinet.


Wrap the machine in plastic sheeting.
Transport packing
A wooden crate is required for overland transport to protect the machine from mechanical
damage.
Consult an authorised KAESER service agent for advice on packing for sea or air transport.

12.3 Storage
Pre --- condition: The machine is adequately packed.

Store the machine in a dry, frost ---free room.


Prevent entry of moisture and condensation.

12 --- 68
 De --- commissioning, Storage and Transport

12.4 Transporting
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.
Fork truck
Pre --- condition: The whole machine is over the forks.

Fig. 30 Transport by fork truck

Lifting cradle
Pre --- condition: No pressure on the sides of the machine cabinet.

Fig. 31 Transport by lifting cradle

12.5 Disposal
Pre --- condition: Machine is de---commissioned.

The sealed refrigerant circuit still contains both refrigerant and oil.
Both must be drained and disposed of by an authorised body.
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 drain the cooling oil from the machine.
Remove used ail filter and separator cartridge.
Hand the machine over to an authorised disposal expert.

12 --- 69
 Annex

13 Annex

13.1 Conformity
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 Diagrams and Drawings

13.2.1 Pipeline and instrument flow diagram (P&I diagrams)

13 --- 70
 Appendix

13.2.2 Pipeline and instrument flow diagram (option C1)

13 --- 76
 Appendix

13.2.3 Dimensional Drawing

13 --- 82
 Appendix

13.2.4 Electrical diagram

13 --- 85