SERVICE MANUAL

Screw Compressor
Model: SK 21 / 15 bar SIGMA CONTROL
No.: SK_C_1727190_10---000_00E

Manufacturer:

KAESER KOMPRESSOREN GmbH

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

1.1 Using the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Further Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Symbols and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4.2 Other 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 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.9.2 Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8

3.1 Specified Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.2 Unspecified Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.3 User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 8
3.3.1 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 9
3.3.2 Adherence to inspection schedules and accident prevention regulations 3 --- 9
3.4 Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.4.1 Awareness of danger sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.4.2 Safe machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.4.3 Organising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.4.4 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.5 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14
3.6 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14
3.7 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.7.1 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.7.2 Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.8 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.9 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 16

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4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

4.1 Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
4.1.1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
4.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.1.3 Volt ---free Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.2.1 Machine mountings (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.2.2 Optional filter monitoring set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.3 Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.3.1 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.3.2 Tasks of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
4.3.3 Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.3.4 Modulating control (option C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.5 SIGMA CONTROL Keys and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21

5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 23

5.1 Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 23
5.2 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 23
5.2.1 Place of installation and space required . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 23
5.2.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24
5.2.3 Operating in a compressed air network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.2 Reporting Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.3 Install the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
6.5 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28
6.5.1 Machine fixing (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28

7 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29

7.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.2 To be Observed Before Every Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.3 Check Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.4 Setting the overload protection cut ---out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.5 Pour cooling oil into the airend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.6 Checking Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
7.7 Check the interlock switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 32
7.8 Initial Start–up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 33
7.9 System pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34

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8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.1 Switching on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.1.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
8.1.2 Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
8.1.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
8.2 Switching Off in an Emergency and Switching On Again . . . . . . . . . . . . . . . . 8 --- 36
8.3 Remote On and Off Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37
8.4 Switching On and Off with the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37
8.5 Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . 8 --- 37
8.5.1 Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
8.5.2 Resetting warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38

9 Event Recognition and Fault Rectification . . . . . . . . . . . . . . . . . . . . . . 9 --- 39

9.1 Alarm messages to the controller
(machine shut ---down, red LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.2 Warning messages on the controller (yellow LED flashes) . . . . . . . . . . . . . . . 9 --- 42
9.3 Other Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 45

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 47
10.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 47
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 48
10.2.1 Resetting maintenance interval counters . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 48
10.2.2 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 49
10.2.3 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
10.2.4 Regular Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
10.3 Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.4 Filter Mat Maintenance (control cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.5 Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.6 Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.7 Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.7.1 Check the belts and their tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.7.2 Changing the belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.8 Checking the pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.9 Manually Venting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
10.10 Checking and Topping Up the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.10.1 Checking cooling oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.10.2 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.11 Changing the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 60
10.12 Oil Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 63
10.13 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 64
10.14 Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 66

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11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67

11.1 Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67
11.2 Ordering Maintenance Parts and Operating Materials . . . . . . . . . . . . . . . . . . 11 --- 67
11.3 Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67
11.4 Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67
11.5 Spare Parts for Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 68

12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . . 12 --- 71

12.1 De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 71
12.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 71
12.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 72
12.4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 72
12.4.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 72
12.4.2 Fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 72
12.4.3 Transverse beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 73
12.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 73

13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 74
13.1 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 74
13.1.1 Pipeline and instrument flow diagram (P&I diagrams) . . . . . . . . . . . . . . . 13 --- 74
13.1.2 Pipeline and instrument flow diagram (option C1) . . . . . . . . . . . . . . . . . . . 13 --- 80
13.1.3 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 86
13.1.4 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 89

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Fig. 1 Maximum relative humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4

Fig. 2 Location of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
Fig. 3 General view of the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
Fig. 4 Machine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
Fig. 5 Machine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
Fig. 6 SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Fig. 7 SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
Fig. 8 Installation recommendation, dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24
Fig. 9 Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
Fig. 10 Control Transformer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 27
Fig. 11 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28
Fig. 12 Airend filling port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
Fig. 13 Interlock switch position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 32
Fig. 14 Label: Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 33
Fig. 15 Switching on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 35
Fig. 16 Switching off in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 36
Fig. 17 Acknowledging and resetting warning and alarm messages . . . . . . . . . . . . . 8 --- 37
Fig. 18 Cooler filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
Fig. 19 Control cabinet ventilation grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
Fig. 20 Air filter maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
Fig. 21 Re---tension the belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
Fig. 22 Belt changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
Fig. 23 Venting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
Fig. 24 Check the cooling oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Fig. 25 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
Fig. 26 Changing the cooling oil, oil separator tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 61
Fig. 27 Changing the cooling oil, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 62
Fig. 28 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 63
Fig. 29 Changing the oil separator cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 65
Fig. 30 Transport by fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 72
Fig. 31 Transport with lifting cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 73

v
 Table Directory
Chapter --- page

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

Tab. 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 3 Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 8 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 9 Compressor motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 10 Recommended cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 11 Cooling oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 12 Power connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 13 Inspection schedule for Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
Tab. 14 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
Tab. 15 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14
Tab. 16 SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
Tab. 17 SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
Tab. 18 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24
Tab. 19 Re---starting after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
Tab. 20 Installation conditions checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
Tab. 21 Alarm messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 42
Tab. 22 Warning messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 45
Tab. 23 Other faults and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
Tab. 24 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 49
Tab. 25 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
Tab. 26 Regular service work intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 50
Tab. 27 Check the cooling oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Tab. 28 Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 66
Tab. 29 Machine maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 67

vi
 Regarding this Document

1 Regarding this Document

1.1 Using 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 to the next owner/user of the machine.
. Ensure that all amendments received are entered in the manual.
. Enter details from the machine nameplate and individual equipment in the table in
chapter 2 ”Technical Specifications”.

1.2 Further Documents

Included with this service manual are documents intended to assist in the safe operation of
the machine:
D certificate of acceptance / operating instructions for the pressure vessel,
D manufacturer’s declaration or declaration of conformity in accordance with applicable
directives,
D SIGMA CONTROL service manual.
. Make sure all documents are complete and take notice of the their contents.
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. Please contact KAESER if you have any queries
regarding the use and duplication of this documentation. We will gladly help you in the ap-
propriate use of the information.

1.4 Symbols and Identification

1.4.1 Warnings

Here are given the type and source of the danger.

DANGER The possible consequences of ignoring a hazard warning are shown here.
The word ’DANGER’ means that death or severe injury can result if the warn-
ing notice is ignored.
. Here are given the measures to protect yourself from the danger.
. Always read and comply with warning notices.
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the
danger symbol.

Signal word Meaning Consequences of ignoring

DANGER Warning of an imminent Death or serious injury may result.
threat of danger
WARNING Warning of possible Death or severe injury or serious damage to
danger the machine is possible.
CAUTION Warning of a possibly dan- Light injury or material damage is possible.
gerous situation.

1 --- 1
 Regarding this Document

1.4.2 Other notices and symbols

. This symbol indicates a task to be carried out.

This symbol identifies environmental protection measures.

This symbol indicates particularly important information.

1 --- 2
 Technical Specification

2 Technical Specification

Model designation and important technical information is found on the machine’s name-
plate. The nameplate is located on the outside of the machine:
D above the cooler, or
D on the rear of the machine.
. Please enter here the 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 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
Optional filter monitoring C2
Transformer power supply for refrigeration T2
dryer
Tab. 2 Options

2.1 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on
equipment fitted.

Weight [kg] 320

Tab. 3 Machine weight

2.2 Temperature
Minimum cut ---in temperature [˚C] 3
Typical airend discharge temperature during 75 -- 100
operation [˚C]
Max. airend discharge temp. (automatic 110
shut ---down) [˚C]
Tab. 4 Machine temperatures

2 --- 3
 Technical Specification

2.3 Ambient conditions

Maximum elevation above sea level* [m] 1000
Ambient temperature [˚C] 3 --- 45
Inlet air / cooling air temperature [˚C] 3 --- 45
Maximum relative humidity of the intake air see Fig. 1
* Higher elevation permissible only after consultation with the manufacturer
Tab. 5 Ambient conditions

Fig. 1 Maximum relative humidity

T Intake air temperature [˚C]

H Maximum relative humidity [%]

2.4 Pressure
See nameplate for maximum working pressure

Blow--off setting of the pressure relief valve 16,0

[bar]
Tab. 6 Pressure relief valve setting

2.5 Delivery
Delivery [m3/min] 1,12
Tab. 7 Delivery

2.6 Sound Pressure Level

Operational state
D under load at rated speed, rated delivery and rated pressure.
Measuring conditions:
D Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance

Sound pressure level [dB(A)] 65

Tab. 8 Sound Pressure Level

2 --- 4
 Technical Specification

2.7 Motors and Performance

2.7.1 Compressor motor

Rated power [kW] 11

Nominal speed [rpm] 3540
Enclosure protection IP 54
Tab. 9 Compressor motor data

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.

Appropriate measures must be taken (see chapter 8.1) to prevent the

build---up of condensate in shipboard compressors.

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.
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)

2 --- 5
 Technical Specification

SIGMA SIGMA SIGMA

FLUID PLUS / S-- 460 FLUID MOL FLUID FGL / FGH
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. 10 Recommended cooling oil

2.8.2 Cooling oil quantity

Total charge [l] 7,0

Topping up volume [l] (minimum – maxi- 0,3
mum)
Tab. 11 Cooling oil volume

2.9 Electrical Connection

See electrical diagrams in chapter 13.1.4.

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.

General requirements
The machine may only be operated from an earthed TN or TT three---phase supply.
Connection to an IT supply is not permitted without further measures (insulation monitor-
ing).
Further requirements
Further requirement for the three---phase supply apply to machines with:
D frequency---controlled drive,
D integrated refrigeration dryers powered from a transformer,
D separate refrigeration dryers powered from a transformer.
The machine may only be connected to earthed TN and TT three---phase mains supplies
where the star point is earthed.
The machine may not be connected to a three---phase supply where one of the phases is
earthed as this can lead to dangerous voltage surges.
Connection to an IT supply is not permitted without further measures (insulation monitor-
ing, specially designed frequency converter, etc.).

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
and laying method C. If other conditions prevail (higher temperature, non---standard cable
laying or cable lengths above 50 m) the cross---section should be checked and adjusted
accordingly.
Nominal voltage: 440V±10%/3/60Hz

Pre---fuse [A] 25
Supply line [mm2] 4x4
Consumption [A] 20
Tab. 12 Power connection data

2 --- 7
 Safety and Responsibility

3 Safety and Responsibility

Disregard of these instructions can result in serious injury.

DANGER
. Read the service manual carefully and take notice of the contents for
safe machine operation.
The machine is manufactured to the latest engineering standards and acknowledged
safety regulations. Nevertheless, the dangers can arise by its operation:
D Danger to life and limb of the operator or third parties
D Detrimental to the machine and property.
. Use this machine only if it is in a technically perfect condition and only for the purpose
for which it is intended, observing all safety measures and the instructions in the ser-
vice manual.
. In particular, immediately rectify (have rectified) any faults that could be detrimental to
safety.

3.1 Specified Use

D 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 re-
sulting from such unspecified use or application. The risk involved in such unspecified
use is taken solely by the user.
D Specified use also includes compliance with the instructions in this manual.
. Operate the machine only within its performance limits and under the permitted ambi-
ent conditions.

3.2 Unspecified Use

. Never direct compressed air at persons or animals.
. Do not use untreated compressed air for breathing purposes.
. Do not use untreated compressed for any application that will bring it into direct con-
tact with foodstuffs.
. Cooling air, warmed after passing through the machine, may be used for heating pur-
poses but only when it poses no health risk to humans or animals. If necessary, the
warmed cooling air should be treated to render it harmless.
. Do not allow the machine to take in toxic, acidic, flammable of explosive gases or va-
pours.
. Do not operate the machine in areas in which specific requirements with regard to ex-
plosion protection are applied.

3.3 User’s Responsibilities

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

3 --- 8
 Safety and Responsibility

3.3.1 Qualified personnel

Ensure that operating, installation and maintenance personnel are qualified and authorised
for their tasks.
These are people who, by virtue of their training, knowledge and experience as well as
their knowledge of the prevailing conditions, can assess the work to be done and recogn-
ise the possible dangers involved.
Operating personnel
Authorised operating personnel:
D must be of legal age,
D must be conversant with and adhere to the safety instructions and sections of the ser-
vice manual relevant to operation of the machine,
D must have received adequate training and authorisation to operate electrical and com-
pressed air devices
D in the case of machines with refrigeration dryers, they must have training and qualifica-
tion for safe operation of refrigeration devices.

Installation and maintenance personnel

Authorised installation and maintenance personnel:
D must be of legal age,
D must have read, be conversant with and adhere to the safety instructions and sections
of the service manual applicable to installation and maintenance,
D must be fully conversant with the safety concepts and regulations of electrical and
compressed air engineering.
D in the case of machines with refrigeration dryers, must be conversant with safety con-
cepts and regulations relating to refrigeration equipment,
D must be able to recognise the possible dangers of electrical and compressed air de-
vices and take appropriate measures to safeguard persons and property,
D in the case of machines with refrigeration dryers, must be able to recognise the poss-
ible dangers of refrigeration devices and take appropriate measures to safeguard per-
sons and property,
D must have received adequate training and authorisation for the safe installation and
maintenance on these machines.

3.3.2 Adherence to inspection schedules and accident prevention regulations

The machine is subject to local inspection schedules.
Operation in Germany, for example:
D recurring inspections to BGR 500, chapter 2.11:
The user must ensure that the safety devices of the machine are subject to function checks
as required but at least annually.
D Oil changes to BGR 500, chapter 2.11:
The user must have the compressor oil changed as required but at least annually and this
must be documented. This requirement may be waved if analysis proves the oil to be
further usable.

3 --- 9
 Safety and Responsibility

D 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. 13 Inspection schedule for Germany

3.4 Dangers
The general safety instructions in this chapter indicate the possible dangers and how to
deal with them.
Special safety instructions are found in this service manual at the beginning of each
chapter or directly before handling instructions.

3.4.1 Awareness of danger sources

Here are to be found the various types of danger that can arise in connection with machine
operation.

Electricity
. Allow only qualified electricians or trained personnel under the supervision of a quali-
fied electrician to work on electrical equipment according to electrical engineering re-
gulations.
. Before initial start ---up, make sure that adequate protection against electric shock from
direct or indirect contact with the machine is installed and checked.
. Isolate all phases of the main power supply.
. Check that there is no voltage present.
. Switch off any external power sources.
These can be, for example, power supplied through a volt ---free (dry) contact or electri-
cal machine heating.
. Use fuses corresponding to the machine power.
. Regularly check that all electrical connections are tight.

Pressure forces
Compressed air is a contained force. Uncontrolled release of this energy can cause seri-
ous injury or death.
Before all work on a pressure system:
. close shut ---off valves or otherwise isolate the machine from the air network to ensure
that no compressed air can flow back into the machine,
. de---pressurize all pressurized components and enclosures.
. Do not carry out welding, heat treatment or mechanical modifications to pressure com-
ponents (e.g. pipes and vessels) as this influences the component’s pressure resis-
tance.
The safety of the machine is then no longer ensured.

3 --- 10
 Safety and Responsibility

Compressed air quality

. Use appropriate systems for air treatment before using the compressed air from this
machine as breathing air and/or for the processing of foodstuffs.
. Never directly inhale compressed air.
. Use foodstuff---compatible cooling oil whenever compressed air is to come into con-
tact with foodstuffs.
Spring forces
Springs under tension or compression represent contained energy. Uncontrolled release of
this energy can cause serious injury or death.
Minimum pressure/check valves, pressure relief valves and inlet valves are powerfully
spring---loaded.
. Do not open or dismantle valves.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can
result in serious injury.
. Do not open the enclosure while the machine is switched on.
. Isolate all phases of the main power supply.
. Check that there is no voltage present.
. Wear close---fitting clothes and a hair net if necessary.
. Make sure all covers and safety guards are in place and secured before switching on.
Temperature
. Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air
lines, coolers, oil separator tanks, motors and machine heaters.
. Wear protective clothing.
. When welding is taking place on or near the machine take adequate measures to en-
sure that no parts of the machine or any oil vapours can ignite because of sparks or
heat.
Noise
. Operate the machine only with soundproofing in place.
. Wear hearing protection if necessary.
The pressure relief valve blowing off can be particularly loud.
Operating materials
. Strictly forbid fire, open flame and smoking.
. Follow safety regulations when dealing with lubricants and chemical substances.
. Avoid contact with skin and eyes.
. Do not inhale oil mist or vapour.
. Do not eat or drink while handling cooling and lubricating fluids.
. Keep suitable fire extinguishing material on hand.
. Use only KAESER approved operating materials.
Unsuitable spare parts
. Use only spare parts approved by the manufacturer for use in this machine. Unsuit-
able spare parts compromise the safety of the machine.
. Use only genuine KAESER parts for pressure components.

3 --- 11
 Safety and Responsibility

Conversion or modification of the machine

. Do not permit conversion or modification of the machine as this can compromise func-
tion and safe working.
Extension or modification of the compressed air station
. If a compressed air installation is to be extended or modified, check the blow ---off ca-
pacity 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.

3.4.2 Safe machine operation

Here is found information to support safe conduct with the machine.
Transport
. Use suitable lifting gear that conforms to local safety regulations.
. Attach lifting gear only to the designated points on the machine.
. Make sure the centre of gravity is correctly positioned to avoid the machine tipping.
. Make sure the danger zone is clear.
Installation
. Make sure no power is applied when electrical connections are made.
. Only use only electrical cables that are suitable and approved for the the loads ap-
plied.
. Install or remove pressure lines only when they are in the depressurised condition.
. Only use pressure lines that are suitable and approved for the maximum working pres-
sure and medium used.
. Do not allow connecting pipes to be under mechanical stress.
. Do not step onto machine components to climb up the machine.
Location
. Install the machine in a suitable room.
If installed outdoors, the machine must be protected from frost, direct sunlight, dust
and rain.
. The machine is not explosion---proof.
Do not operate in areas in which specific requirements with regard to explosion
protection are applied.
For instance, the requirements of the ATEX directive 94/9/EC ”Equipment and Protec-
tive Systems for use in Explosive Atmospheres”.
. Ensure adequate ventilation.
. Observe the required ambient conditions:
D ambient temperature and humidity,
D clean inlet air with no damaging contaminants,
D inlet air free of explosive or chemically unstable gases or vapours,
D inlet air free of acid---forming substances, particularly ammonia, chlorine or hydro-
sulphide.
. Do not position the machine in the warm exhaust air from other machines.
. Ensure accessibility so that all work on the machine can be carried out without danger
or hindrance.

3 --- 12
 Safety and Responsibility

Operation
. Keep the machine enclosure closed for safety and correct cooling function.
. Carry out regular inspections:
D for damage,
D of the safety devices,
D of the EMERGENCY STOP function,
D of components needing to be monitored.
. Machines drawing in air from the surroundings should not be operate without an air
filter.
Maintenance
. Make sure the machine is disconnected from electrical power, is voltage---free and de-
pressurised before commencing any maintenance work.
. Wear close---fitting, flame---resistant clothing. Wear protective clothing as necessary.
. Do not leave any loose components, tools or cleaning rags on the machine.
. Components removed from the machine can still be dangerous.
Do not open or destroy removed components as some (inlet valves, for instance) are
powerfully spring---loaded.
Decommissioning / disposal
. Drain all fluids from the machine, e.g. cooling oil and water, and dispose of in accord-
ance with local environmental regulations.
. Give refrigerant only to authorised bodies for disposal.
. Dispose of the machine in accordance with local environmental regulations.

3.4.3 Organising
. Designate personnel and their responsibilities.
. Give clear instructions on reporting faults and damage to the machine.
. Give instructions on fire reporting and fire---fighting measures.

3.4.4 Danger zones

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

Activity Danger zone Authorised personnel

Transport 3 m radius from the machine Installation or transport per-
sonnel.

All personnel excluded dur-

ing transport.
Beneath the lifted machine. All personnel excluded!
Installation Within the machine. Installation personnel
1 m radius of the machine and power
lines.
Operation 1 m radius from the machine Operating personnel
2 m radius from the cooling air discharge.
Maintenance Within the machine. Maintenance personnel
1 m radius from the machine
Tab. 14 Danger zones

3 --- 13
 Safety and Responsibility

3.5 Safety Devices

Do not change, bypass or disable safety devices.

Do not remove or obliterate labels and notices.

Ensure that labels and notices are clearly legible.

More information on safety devices is contained in chapter 4 ’Design and Function’, sec-
tion 4.4 ’Safety Devices’.

3.6 Safety Signs

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

Loca- Sign Meaning

tion
1 Electric voltage
Danger of fatal injury from touching electrically live components.
. Isolate all phases of the main power supply.
. Ensure that the power supply cannot be switched on again
(lock off).
. Check that no voltage is present.
2 Hot surface
Danger of burns from touching hot components.
. Do not touch the surface
. Wear long---sleeved garments (not synthetics such as polyester)
and protective gloves.
3 Rotating components
Danger of serious laceration or even severing, particularly of
fingers.
. Operate the machine only with fully closed safety guards, ac-
cess doors and panels.
. Isolate from the mains and lock off before opening any machine
enclosure or guard.
4 Automatic starting
Danger of injury from the machine starting automatically or by re-
mote start command.
. Isolate from the mains and lock off before opening any machine
enclosure or guard.
5 Danger of fatal injury from pressure and spring force if the
valve is incorrectly opened.
. Do not open or dismantle the valve.
. Call for authorised service if a fault occurs.
7 Wrong cooling oil level
Machine damage or excessive oil remaining the compressed air.
. Check the oil level regularly and top up as necessary.
Tab. 15 Safety signs

3 --- 14
 Safety and Responsibility

Fig. 2 Location of safety signs

3.7 Emergencies

3.7.1 Fire fighting

. Immediately disconnect the machine’s voltage supply.
If applicable:
. Cooling water: Shut ---off cooling water supply.
. Heat recovery system: Shut ---down external heating circulation.
Suitable extinguishing agents:
D Foam
D Powder
D Carbon dioxide
D Sand or earth
Unsuitable or unsafe extinguishing agents:
D Intense water jet.

3.7.2 Cooling oil

Skin contact:
. wash off immediately
Eye contact:
. rinse thoroughly with lukewarm water and seek medical assistance.

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.

3 --- 15
 Safety and Responsibility

3.9 Warranty
This service manual contains no independent warranty committment.
Our general terms and conditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is in-
tended under the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with
the user to determine its suitability for his specific application.
. Obtain confirmation from the manufacturer that the machine is suitable for your spe-
cific application.
Furthermore, we accept no warranty obligation for:
D the use of unsuitable parts or operating materials,
D unauthorised modifications,
D incorrect maintenance,
D incorrect repair.
Correct maintenance and repair includes the use of genuine Kaeser spare parts and oper-
ating materials.

3 --- 16
 Design and Function

4 Design and Function

4.1 Machine Overview

4.1.1 Cabinet

Fig. 3 General view of the enclosure

1 Control cabinet door

2 Latch
3 Removable panel
4 Oil level indicator viewing window
The cabinet, when closed, serves various purposes:
D Sound damping
D Protection
D 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 --- 17
 Design and Function

4.1.2 Function
An air–cooled machine serves to illustrate function.

Fig. 4 Machine overview

1 Inlet valve 6 Control cabinet
2 Minimum pressure/check valve 7 Oil separator tank
3 Compressor motor 8 Air filter
4 Oil filter 9 Oil / air cooler
5 Airend

Machine
Ambient 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 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 injec-
tion. Pressure within the machine keeps the oil circulating. A separate pump is not necess-
ary. 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 (2) into the aftercooler (9). The minimum pressure/check valve
ensures there is always sufficient internal 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.

4.1.3 Volt-- free Contacts

Volt ---free contacts are provided for passing messages.
Information on location, load and type of message is to be found in the electrical diagram.
If the volt ---free contacts are connected to an external power source they
may be under power even when the machine is isolated from the supply.

4 --- 18
 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. 5 Machine mountings

4.2.2 Optional filter monitoring set

Sensors monitor the operational condition of the filter. Indication is given as soon as main-
tenance is required.
The following filters are monitored:
D Air filter
D Oil filter
D Oil separator cartridge

4.3 Operating States and Control Modes

4.3.1 Operating states

There are three operating states:
D LOAD: the inlet valve is open. The airend delivers compressed air to the system.
The compressor motor runs under full load.
D 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.
D 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.
D 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 maintain system pressure between the set minimum and
maximum values.
According to the individual compressed air demand one of the various control modes avail-
able will provide the optimum duty cycle for the machine.

4 --- 19
 Design and Function

4.3.3 Control Modes

The controller can operate in the following modes:
D DUAL
D VARIO
D QUADRO

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 shorter the idling time setting, the sooner and more frequently the motor is stopped.

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

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

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.
D Increasing air demand
The machine operates between PARTIAL LOAD and LOAD.
D Falling air demand
The machine operates between PARTIAL LOAD, IDLE RUNNING and STANDSTILL.

4.4 Safety Devices

The following safety devices are provided and may not be modified:
D EMERGENCY STOP button
The EMERGENCY STOP button shuts down the compressor immediately. The motor
remains still. The pressure system is vented.
D Pressure relief valve
The pressure relief valve protects the system from excessive pressure. This is factory
set.
D Door interlock switch
The machine will stop automatically if a safety interlocked door or panel is opened or
removed.
D Housing and covers for moving parts and electrical connections.
Protection from accidental contact.

4 --- 20
 Design and Function

4.5 SIGMA CONTROL Keys and Indicators

Fig. 6 SIGMA CONTROL keys

Symbol Item Description Function

1 ON (I) Switch the machine on.
Programmed operating mode is active.
2 OFF (0) Switch the machine off.

3 Operating mode: Switching clock ---control on and off.

Clock The LED lights when the machine is under clock
control.
4 Operating mode: Switching remote control on and off.
Remote control
The LED illuminates when the machine is under re-
mote control.
5 Operating mode: Toggles the machine between LOAD and IDLE.
LOAD / IDLE
6 Arrow key Scrolls down menu.
Reduces a parameter value.
7 Arrow key Scrolls menu up.
Increases a parameter value.
8 Escape Returns to the next higher menu level.
Exits the edit mode without saving.
Returns to the main menu when held down at least
10 seconds.
9 Return/enter/save Only affects the message in the third line of the dis-
key play (12).
Returns to the selected submenu.
Saves and leaves the edit mode.

4 --- 21
 Design and Function

Symbol Item Description Function

10 Events and infor- Displays the event memory.
mation key
Selection from every menu.
Returns together with ’esc’ key (8).
11 Acknowledge (re- Acknowledges (re---sets) messages and resets the
set) key event memory (if permitted).
Tab. 16 SIGMA CONTROL keys

Fig. 7 SIGMA CONTROL indicators

Symbol Item Description Function

12 Display Alphanumeric display with 4 lines.

13 Alarm Blinks red when an alarm occurs.

Lights continuously when acknowledged.
14 Communication Lights red if communication via the Profibus is inter-
rupted.
15 Service/warning Blinks yellow for:
LED --- maintenance work required
--- warning message
16 Controller power Lights green when the power supply to the controller
ON is switched on.
17 LOAD Lights green when the machine is in the operating
state LOAD

18 Operating mode Lights green when the machine is in the IDLE mode.
IDLE
Blinks green if the manualLOAD/IDLING changeover
key (5) is used.
19 Machine ON The machine is switched on.

Tab. 17 SIGMA CONTROL indicators

4 --- 22
 Installation and Operating Conditions

5 Installation and Operating Conditions

5.1 Surroundings
. Strictly forbid fire, open flame and smoking.
. When welding is taking place on or near the machine take adequate measures to en-
sure that no parts of the machine or any oil vapours can ignite because of sparks or
heat.
. The machine is not explosion---proof.
Do not operate in areas in which specific requirements with regard to explosion
protection are applied.
For instance, the requirements of the ATEX directive 94/9/EC ”Equipment and Protec-
tive Systems for use in Explosive Atmospheres”.
. Observe the required ambient conditions:
D ambient temperature and humidity,
D clean inlet air with no damaging contaminants,
D inlet air free of explosive or chemically unstable gases or vapours,
D inlet air free of acid---forming substances, particularly ammonia, chlorine or hydro-
sulphide.
. suitable fire extinguishing material at hand.

5.2 Installation Conditions

5.2.1 Place of installation and space required

Pre–condition: The floor must be level, firm and capable of bearing the weight of the
equipment.

The spacings given are recommended and ensure unhindered access to

all machine parts.
Please consult KAESER if they cannot be achieved.

. If installed outdoors, the equipment must be protected from frost, direct sunlight, dust
and rain.
. Ensure accessibility so that all work on the machine can be carried out without danger
or hindrance.

5 --- 23
 Installation and Operating Conditions

Fig. 8 Installation recommendation, dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Inlet air opening

5.2.2 Ventilation
Values given are minimum guide values.

If the inlet aperture is insufficient a dangerous vacuum can be created in

the machine 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.

SK 21 SK 24
Inlet opening [m@] 0.3 0.35
Extractor for forced venti- 4000 5000
lating:
Flow rate [m#/h] at 100 Pa
Exhaust air duct: 350 x 600 350 x 600
Dimensions [mm]
Tab. 18 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 13.1.3.

5 --- 24
 Installation and Operating Conditions

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 --- 25
 Installation

6 Installation

6.1 Safety
Voltage!

DANGER There is danger of fatal injury caused by touching electrically live compo-
nents.
. Isolate all phases of the main power supply.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Check that no voltage is present.

Uncontrolled pressure release!

WARNING Serious injury or death can result from loosening or opening components
under pressure.
. De---pressurize all pressurized components and enclosures.

Minimum pressure/check valves, pressure relief valves and inlet

valves are powerfully spring-- loaded.
WARNING
Fatal injury may occur from incorrect opening of spring---loaded compo-
nents.
. Do not open or dismantle valves.
Installation work may only be carried out by authorised personnel!

All functioning parts are factory set.

Changes may not be made without the permission of the manufacturer.

6.2 Reporting 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 --- 26
 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 13.1.4)

1 1 3

1 1 3

Fig. 10 Control Transformer Connection

1 Primary
2 Secondary
3 Mains supply

6 --- 27
 Installation

. Connect the machine to the mains power supply in accordance with Fig. 11 and the
electrical diagram in chapter 13.1.4.

Fig. 11 Electrical Connection

1 User ---provided main switch and fusing

6.5 Options

6.5.1 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 13.1.3.
. Use appropriate bolts to anchor the machine.

6 --- 28
 Initial Start-up

7 Initial Start---up

7.1 Safety
Voltage!

DANGER Contact with live electric components can cause serious injury or death.
. Isolate all phases of the main power supply.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Check that no voltage is present.

Uncontrolled pressure release!

WARNING Serious injury or death can result from loosening or opening components
under pressure.
. 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 .
Initial start ---up may only be carried out by authorised personnel!

Before switching on ensure that:

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

7.2 To be Observed Before Every Initial Start ---up

Initial start ---up of the machine may only be carried out by trained and authorised installa-
tion or maintenance personnel.
Incorrect or improper initial start ---up can cause personal injury or damage to the machine.
After initial start ---up it is necessary for the compressor to be run under full
load for at least 30 minutes every week.

Special measures on re-- starting after storage

Storage period longer Remedy
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.
Tab. 19 Re ---starting after storage

7 --- 29
 Initial Start-up

7.3 Check Installation and Operating Conditions

Carry out all the items in the checklist before starting the machine.

To be checked Chapter Done?

1 . Are the operators fully conversant with safety regulations?
2 . Are all the conditions for installation fulfilled? 5
3 . Machine anchored to the floor? 6.5.1
(option H1)
4 . Is the power supply as specified on the nameplate? 2
5 . Supply cable section and fuse rating adequate? 2.9.2
6 . User’s lockable supply disconnecting device installed? 6.4
7 . All electrical connections checked for tightness?
8 . Shut ---off valve fitted to compressed air outlet? 6.3
9 . Connection made to air main with hose or axial compen- 6.3
sator?
10 . Belt tension checked? 10.7
11 . Required quantity of cooling oil poured into the airend? 7.5
12 . Correct level of oil showing in the level indicators? 10.10.1
13 . Door interlock switch aligned and function checked? 7.7
14 . Are all access doors closed and latched and all removable 4.1.1
panels in place and secured?
Tab. 20 Installation conditions checklist

7 --- 30
 Initial Start-up

7.4 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).
To prevent the overload protection cutout from being triggered by voltage fluctuations, tem-
perature influences or component tolerances, the setting can be higher than the arithmeti-
cal phase current.

7.5 Pour cooling oil into the airend.

Material: 0.5 l cooling oil

Pre–condition: Machine switched off.

Supply disconnecting device switched off and 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. 12 Airend filling port

1 Screw plug
2 Airend

. Remove the plug (1) from the airend (2).

. Pour oil into the airend and replace the screw plug.
. Turn the rotors over by hand by means of the belt pulley to distribute the oil.

7.6 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 --- 31
 Initial Start-up

7.7 Check the interlock switch

Pre–condition: Machine switched off.
Mains power switch off and locked out.

The machine may only be operated with a fully functional interlock switch.
The interlock switch stops the machine as soon as the access panel is
opened.

Fig. 13 Interlock switch position

1 Interlock switch
2 Removable panel

Check the interlock switch function on initial start ---up.

Consult an authorised KAESER service agent if the interlock switch fails to

switch off the machine.

. Open the access panel (2) after switching on the machine.

The machine switches off automatically. The controller displays an alarm message.
. Close the panel and acknowledge the alarm.

7 --- 32
 Initial Start-up

7.8 Initial Start–up

. Open the shut–off valve to the air network.
. Switch on at the main supply isolator.
After the controller has carried out a self–test, the green ’Power ON’ LED illuminates.

Changing the display language

The controller can display text messages in several languages:

Bulgarian Finnish Portuguese

Chinese French Romanian
Chinese (Taiwan) French (Canada) Russian
Croatian Greek Swedish
Czech Indonesian Slovenian
Danish Italian Spanish
Dutch Japanese Spanish (Mexico)
English Korean Turkish
English (USA) Norwegian ...
Estonian Polish

Fig. 14 Label: Setting the language

1 . If required: Deactivate 5 . Press the return key to enter the

EMERGENCY STOP language selection menu.
2 . If required: Acknowledge alarm 6 . Press the UP or Down keys as re-
message. quired until the desired language
selection is shown.
3 . Keep the Escape key pressed for 7 . Press the return key to select the de-
5 seconds to change to the standard sired language.
menu.
4 . Press the UP key 8 times. 8 . Keep the Escape key pressed for
5 seconds to change to the standard
menu.

You can remove the label after you have set the language.

7 --- 33
 Initial Start-up

Switching the machine on

. Press the ’LOAD/IDLE mode’ key.
. Press the ON key.
The green ’Machine ON’ LED illuminates.
. Allow the machine to idle for at least one minute.
This ensures that cooling oil is distributed throughout the system.
. Press the ’LOAD/IDLE mode’ key.
The machine switches to LOAD status and delivers compressed air.

Keep an eye on the machine during the first few hours of operation to en-
sure that it is operating correctly.

After the first 50 operating hours carry out the following:

. Check that all electrical connections are secure.

7.9 System pressure setting

The system pressure p1 is factory set to the highest possible value.
Adhustment is necessary for individual operating conditions.
. System pressure setting is described in the SIGMA CONTROL service manual.

The machine may toggle a maximum of twice per minute between LOAD
and IDLE.

Reducing starting frequency:

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

7 --- 34
 Operation

8 Operation

Fig. 15 Switching on and off

1 ’Machine ON’ LED (green) 5 ’Remote’ key
2 ’ON’ key (’I’) 6 ’LOAD’ LED
3 OFF key (’0’) 7 ’IDLE’LED
4 ’Clock’ key 8 ’Power ON’ LED (green)
13 LOAD/IDLE toggle key

8.1 Switching on and off

Compressed air!

WARNING Serious injury is possible.

. Never direct compressed air at persons or animals.
Always switch the machine on and off with the ’ON’ and ’OFF’ keys.
The supply disconnecting device is installed by the user.

Once the compressor has been switched on it must run for at least 20 min-
utes under full load before being switched off again.

Shipboard compressors must be run under full load for at least

30 minutes every week at a minimum operating temperature of ≥90˚C to
ensure proper corrosion protection and to prevent build---up of condensa-
tion in the cooling fluid and remove any moisture.

8.1.1 Switching on
. Ensure that:
D no one is working on the machine,
D all panels are in place,
D all access doors are closed,
D no parts of the machine are colder than +3˚C.
. Switch on the supply isolating device.
After the controller makes a self---test the green LED ’Power ON’ (8) lights.
. Press the ’ON’ key (2).
The green LED ’Machine ON’ lights (1).
The compressor motor runs, assuming the network pressure is lower than the cut ---out
pressure.

8 --- 35
 Operation

8.1.2 Automatic restart

Pre–condition: Network pressure is lower than the compressor cut ---out pressure.

Automatic restart is factory---set.

The machine restarts automatically when power is resumed after a power cut.

8.1.3 Switching off

. Press the ’LOAD/IDLE’ toggle key (13).
The machine switches to IDLE and the LED (7) flashes.
. After running in idle for 20 seconds, press the OFF key (3).
The ’Machine ON’ LED goes out (1).
. Switch off and lock out the supply disconnecting device.

8.2 Switching Off in an Emergency and Switching On Again

Fig. 16 Switching off in an emergency

9 EMERGENCY STOP button

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

Pre–condition: Fault rectified.

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

8 --- 36
 Operation

8.3 Remote On and Off Switching

Pre–condition: A remote control device is connected.

Apply the remote warning label to the machine where it is plainly visible.
BEWARE! This machine is remotely controlled and can start at any
time.

Label the remote control device accordingly:

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

. Press the ’Remote’ key (5).

The LED lights. The remote control device has control of the machine.
The machine can still be switched on and off by the ’ON’ and ’OFF’ keys (2 and 3) if re-
quired.

8.4 Switching On and Off with the Clock

Pre–condition: The clock is programmed.

Apply the time---controlled warning label to the machine where it is plainly

visible.
”BEWARE! This machine is clock-- controlled and can start at any
time.”

. Press the ’Clock’ key (4).

The LED lights. The integrated clock has control of the machine.

8.5 Acknowledging and Resetting Warning and Alarm Messages

Fig. 17 Acknowledging and resetting warning and alarm messages

10 ’Warning’ LED (yellow)

11 ’Alarm’ LED (red)
12 ’Acknowledge’ (reset) key

8 --- 37
 Operation

Alarm message
An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11).
The display shows the latest acquired value

Alarm coming LED flashes

Alarm acknowledged LED illuminates
Alarm reset LED out

or

Alarm coming LED flashes

Alarm reset LED flashes
Alarm acknowledged LED out

Warning messages
The display shows a maintenance or warning message.
The yellow warning LED (10) flashes, for example, if a maintenance task is due.
The display shows the latest acquired value

Warning coming LED flashes

Warning acknowledged LED illuminates
Warning reset LED out

or

Warning coming LED flashes

Warning reset LED flashes
Warning acknowledged LED out

8.5.1 Resetting alarm messages

Pre–condition: Fault rectified.

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

The ’Alarm’ LED goes out (11).
The machine is now ready to start again.

8.5.2 Resetting warning messages

Pre–condition: The cause of the alarm is eliminated.

Maintenance task completed.

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

The ’Warning’ LED goes out (10).

8 --- 38
 Event Recognition and Fault Rectification

9 Event Recognition and Fault Rectification

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

Description Indicated by see chapter

An event that triggers an alarm (with automatic Blinking red LED 9.1
shut ---down)
An event that triggers a warning (no shut --- Blinking yellow LED 9.2
down)
Miscellaneous events (faults) No indication 9.3

9.1 Alarm messages to the controller

(machine shut ---down, red LED blinking)
Message Possible cause Remedy
access doors Door open with the machine Close the door(s).
running.


ADT Maximum airend discharge Ensure adequate ventila-

temperature exceeded. tion.
Ensure that the permissible
room temperature is not ex-
ceeded.
Clean the cooler.
Cooling air outlet of the ma-
chine too near a wall.
Check the cooling oil level.
ADT dT/dt Maximum rise rate of airend Check airend and piping to
discharge temperature airend.
(ADT) exceeded. Check the cooling oil level.
Check oil circulation.
AI 3/AI 4 error Line---break between the Check transducer connec-
analog input and the sen- tions and wiring.
sor.
Short circuit to earth.
AI 7/AI 8 error Line---break between the Check transducer connec-
analog input and the sen- tions and wiring.
sor.
Short circuit to earth.
airend rotation The drive motor is turning in Change over phase lines L1
the wrong direction. and L2.
air filter dp Air filter clogged. Clean or renew the filter el-


ement.
backpressure Back pressure in the oil Check venting line.
separator tank caused by
poor venting.
Buscontroller Bus link via the Profibus DP Check line and settings.
interface

9 --- 39
 Event Recognition and Fault Rectification

Message Possible cause Remedy

blowoff prot. The activating pressure of Change the oil separator
the pressure relief valve on cartridge.
the oil separator tank has Open the shut ---off valve in
been exceeded. the venting line.
Condensate drain Fault in condensate drainage. Check condensate drainage.
coolingwater low Cooling water pressure too Check cooling water supply.
low. Check the cooling water
stop valve position.
DO 0.6/DO 0.7 Short circuit in the line be- Check line and connec-
tween DO 0.6 / DO 0.7 out- tions.
puts and a consumer.
DO 1.6/DO 1.7 Short circuit in the line be- Check line and connec-
tween DO 1.6 / DO 1.7 out- tions.
puts and a consumer.
EMERGENCY-STOP Emergency-stop-button Unlatch the pushbutton.
pressed.
ext. message 0 Customer specific:
... No data
ext. message 5
fan M2 I Shutdown of 1st fan motor Investigate cause of shut-


because of overload. down.

Reset overload trip.
fan M3 I Shutdown of 2nd fan motor Investigate cause of shut-


because of overload. down.

Reset overload trip.
fan M4 I Shutdown of 3rd fan motor Investigate cause of shut-


because of overload. down.

Reset overload trip.
HT cell Fault in the high tension Contact KAESER service.
cell.
mains cont. on? The mains contactor does Check mains contactor and
not pull in despite ON com- wiring.
mand.
mains cont. off? The mains contactor does Check mains contactor and
not drop out despite OFF wiring.
command.
mains monitor Fault in mains power supply. Have the mains power sup-
ply checked.
2nd power failure Check power supply volt-


mains voltage
age.
Check door interlock.
Model Machine model uncertain Contact KAESER service.
Drive motor has been shut- Change the oil separator


motor I
down because of overload. cartridge.
Check minimum pressure/
check valve.
Investigate cause of shut-
down.

9 --- 40
 Event Recognition and Fault Rectification

Message Possible cause Remedy

Drive motor overheated. Ensure adequate ventila-


motor T
tion.
Install an extractor.
Clean the motor.
motor bearings Drive motor bearings over- Grease the motor bearings
heated. with the greasing device.
Neutral p---switch Customer specific:
No data
Neutral T---switch Customer specific:
No data
no press.buildup Machine produces no com- Check the machine for
pressed air. leaks.
Working pressure stays Check coupling / V ---belts
below 3.5 bar within a Contact KAESER service.
preset period.
oil p ↓ No changeover to load as Check oil circulation.
long as the minimum oil Check pressure switch, line
pressure is not reached. and connection.
PD temperature Package discharge tem- Contact KAESER service.


perature too low.

PD temperature Package discharge tem- Check the fan motor.


perature too high. Clean the cooler.

Check the cooling oil level.
pRV The activating pressure of Replace the pressure relief


the pressure relief valve on valve.

the oil separator tank has
been exceeded.
RD compr. p Pressure switch for the re- Ensure adequate ventila-


frigerant compressor has tion.

activated. Clean the refrigerant con-
denser.
Clean the cooler.
RD compr. T ↑ Temperature in the refriger- Clean the refrigerant con-
ant dryer too high. denser.
Ensure adequate ventila-
tion.
Install an extractor fan.
Clean the cooler
RD compr. T ↓ Temperature in refrigeration Contact KAESER service.
dryer too low.
separator dp Oil separator cartridge Replace the oil separator


clogged. cartridge.
separator T Maximum air temperature Check the line to the trip


on oil separator tank outlet relay.

exceeded.
SFC Frequency converter faulty. Contact KAESER service.

9 --- 41
 Event Recognition and Fault Rectification

Message Possible cause Remedy

Maximum permissible Ensure adequate ventila-


SIGMA CONTROL T
temperature in SIGMA tion.
CONTROL housing ex- Ensure that the permissible
ceeded. room temperature is not ex-
ceeded.
Check control cabinet venti-
lator (filter mats).
sh.cct.AI 1/AI 2 The connection between Check transducer connec-
the sensor and the analog tions and wiring.
input is shorted.
sh.cct.AI 5/AI 6 The connection between Check transducer connec-
the sensor and the analog tions and wiring.
input is shorted.
soft start Fault in the soft start equip- Contact KAESER service.
ment.
Airend discharge tempera- Heat the compressor room.


Start ture (ADT) too low. Ambient

temperature below +3˚ C.
V ---belts broken The V ---belts parted during Replace the belts.
operation.
Tab. 21 Alarm messages and actions

9.2 Warning messages on the controller (yellow LED flashes)

Message Possible cause Remedy

access doors Doors opened with the ma- Close access doors.
chine shut down.
ADT ↑ Maximum airend discharge Ensure sufficient ventilation
temperature will soon be re- Clean the cooler.
ached.
The machine’s cooling air
outlet is too near a wall.
Check the cooling oil level.
Replace the oil filter.
air filter dp ↑ The pressure drop across Clean/replace the air filter
the air filter is too high. element.
Air filter element clogged.
The interval for the air filter Clean/replace the air filter


air filter h
element check has expired. element.

annual maint. The maintenance interval Carry out necessary main-

counter was not reset within tenance and reset one of the
a year. following maintenance inter-
val counters: oil filter, oil
separator, oil change or air
filter.


bearing maint. h The maintenance interval Grease the motor bearings.

for greasing the bearings
has expired.

9 --- 42
 Event Recognition and Fault Rectification

Message Possible cause Remedy

blowoff prot. Warning Change the oil separator
The blowoff pressure of the cartridge.
pressure relief valve will Open the shut–off valve in
soon be reached. the venting line.
blt.coup.insp.h The maintenance interval Visually inspect and tension
 for V–belt tension / coupling the V–belts.
inspection has expired.
V–belts / coupling worn. Change belts / coupling.


blt.coup.chng. h
Buffer battery Battery for retention of data Replace the battery
is discharged.
bus alarm Bus link via Profibus DP in- Check bus highway and
terface interrupted plug.
Condensate drain Fault in condensate drain- Check condensate drain
age. and lines.
elect. equip. h ↑ The service interval for Reset the service interval
checking electrical equip- counter.
ment and installation has
expired.
error: RS 485 Wrong configuration or Check the link/interface
transmission error. connections between the
two controllers.
Check maximum cable
length and screening.
1 master and 1 slave confi-
gured.
ext.load signal? Dubious external load sig- Check settings of the exter-
nal nal controller.
Increased cut–out pressure Take the pressure drops
exceeded. across filters and dryer into
The external load control account.
has not switched to idle (off
load).
ext. message 0 Customer specific:
... No data
ext. message 5
flash memory Internal controller memory Contact KAESER service.
error.
FC mains Failure of power supply to Check power supply.
the frequency converter.
mains voltage ↓ 1. power failure: Check power supply volt-
Machine was re–started age.
automatically. Check door interlock.
modem problem SIGMA CONTROL does not Check the link between
recognise the modem. SIGMA control and the
modem.
motor T ↑ Drive motor overheating. Ensure adequate ventila-
tion.
Install an extractor.
Clean the motor.

9 --- 43
 Event Recognition and Fault Rectification

Message Possible cause Remedy

motorstarts /h The permissible number of Extend the idle period.


motor starts was exceeded Increase capacity of air re-
during the last 60 minutes. ceiver.
Increase cross–section of
piping between compressor
and air receiver.
motorstarts /d The permissible number of Extend the idle period.


motor starts was exceeded Increase capacity of air re-

during the last 24 hours. ceiver.
Increase cross–section of
piping between compressor
and air receiver.
The service interval for the Have an authorized


motor bearings h
motor bearing change has KAESER technician replace
expired. the motor bearings.
Neutral p–switch Customer specific:
No data
Neutral T–switch Customer specific:
No data
no press.buildup The compressor cannot Check for air leaks.
build–up to working pres- Check the value for internal
sure. pressure given in the ”ana-
log data” menu with the re-
ading on the oil separator
tank pressure gauge.
oil filter dp ↑ Oil filter clogged. Oil filter replacement
oil filter h The interval for the next oil Oil filter replacement


filter check has expired.

oil level ↓ Oil level too low. Top up the cooling oil.
oil T ↓ Cooling oil temperature too Increase room temperature.
low. Check the oil circuit.
Check temperature switch,
line and connection.


oil change h The service interval for the Change the cooling oil.
oil change has expired.
oil content ↑ Warning Check the scavenge tube in
The oil content limit for pure the oil separator cartridge.
air will soon be reached. Check the dirt trap strainer
in the scavenge line.
Check air treatment up-
stream of the measurement.
The oil content limit for pure Check the scavenge tube in


oil content
air has been exceeded. the oil separator cartridge.
Check the dirt trap strainer
in the scavenge line.
Check air treatment up-
stream of the measurement.

9 --- 44
 Event Recognition and Fault Rectification

Message Possible cause Remedy

PD temperature↓ Warning Contact KAESER service.
Compressor outlet (pack-
age discharge) temperature
is low.
PD temperature Warning Clean the cooler.
 Compressor outlet (pack- Check the cooling oil level.
age discharge) temperature
too high.
RAM Internal RAM defective. Contact KAESER service.
set output The ’set output’ test func- Stop the ”set output” mode.
tion is activated.
separator dp ↑ Oil separator cartridge Change the oil separator
clogged. cartridge.
separator h The interval for the next oil Change the oil separator


separator cartridge check cartridge.

has expired.
system press. ↓ System pressure has fallen Check air demand.
below the ”sys.press. low” Check transducer connec-
value. tions and wiring.
Air consumption too high. Check ”sys.press. low” set-
ting.
system press. ↑ System pressure is above Check for air leaks.
(vacuum machines only) the ”sys.press. high” value. Check ”sys.press. high”
setting.
Check if the machine
switches to LOAD.
Tab. 22 Warning messages and actions

9.3 Other Alarms

Fault Possible cause Remedy
Drive motor overload Overload protection cutout Check setting.
protection cutout has is defective or incorrectly
tripped. set.
Oil separator cartridge Check pressure drop across
clogged. the separator cartridge.
Change the oil separator
cartridge if necessary.
The pressure system does Open the shut ---off valve in
not vent. the venting line.
Motor defective; bearing
damage or windings
shorted.
Airend defective.

9 --- 45
 Event Recognition and Fault Rectification

Fault Possible cause Remedy

Machine runs but produces Inlet valve not opening or
no compressed air. only opening partially.
Venting valve not closing.
Leaks in the pressure sys- Check pipework and con-
tem. nections for leaks and
tighten any loose fittings.
Air consumption is greater Check compressed air net-
than the capacity of the work for leaks.
compressor. Shut down the consumer(s).
Hose coupling or mainten- Remove coupling or main-
ance hose still plugged into tenance hose.
the quick ---release coupling
on the oil separator tank.
Cooling oil runs out of the Oil level in the oil separator Drain off oil until the correct
air filter. tank too high. level is reached.
Inlet valve defective.
Compressor switches be- Air receiver too small.
tween load and idle (off Flow into the compressed Increase air pipe diameters.
load) more than twice per air network restricted.
minute. Check filter elements.
Switching difference too
small (e.g. p1 SD)
Cooling oil leaking into the Hose coupling or mainten- Remove coupling or main-
floor pan. ance hose still plugged into tenance hose.
the quick ---release coupling
on the oil separator tank.
Oil cooler leaking
Connections leaking. Tighten connection fittings.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Use SIGMA FLUID cooling
high. oil.
Oil separator cartridge split. Change the oil separator
cartridge.
Oil level in the oil separator Drain off oil until the correct
tank too high. level is reached.
Oil return line clogged. Check dirt trap in the oil re-
turn line.
Tab. 23 Other faults and actions

9 --- 46
 Maintenance

10 Maintenance

10.1 Safety
Any disregard of these instructions and/or incorrect handling may result in serious
injuries.

Voltage!

DANGER There is danger of fatal injury caused by touching electrically live compo-
nents.
. Isolate all phases of the main power supply.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Check that no voltage is present.

Volt ---free contacts may be under power from an external source even
when the machine is isolated from the mains supply.

Minimum pressure/check valves, pressure relief valves and inlet

valves are powerfully spring-- loaded.
WARNING
Fatal injury may occur from incorrect opening of spring---loaded compo-
nents.
. Do not open or dismantle valves.
. Call for authorised service if a fault occurs.

Uncontrolled pressure release!

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 .

Belt drive

WARNING Touching the rotating belt drive can result in severe crushing or even sever-
ance.
. Do not open the enclosure while the machine is switched on.
. Isolate all phases of the main power supply.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Work carefully.

10 --- 47
 Maintenance

Fan wheel

WARNING Touching a rotating fan wheel can result in serious laceration or even sever-
ance.
. Do not open the enclosure while the machine is switched on.
. Isolate all phases of the main power supply.
(switch off the mains supply disconnecting device)
. Ensure that the power supply cannot be switched on again (locked
off).
. Work carefully.

Leakage

CAUTION Leaks result in loss of oil and reduced performance.

Damage or complete breakdown can result.
. Test run on completion of maintenance work.
. Carry out a visual check of the machine.

Maintenance work may only be carried out by authorised personnel!

Before switching on again ensure that:

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

10.2 Maintenance Schedule

Maintenance intervals are recommendations only and should be adjusted
to suit the installation and operating conditions.

According to the way a machine is equipped, sensors and/or maintenance interval

counters monitor the operational state of important functional devices. Necessary mainten-
ance tasks are signalled by the SIGMA controller.
. Keep a log of all service work.
This enables the frequency of individual maintenance tasks to be compared with
KAESER’s recommendations. A list is given in chapter 10.14.

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.
See the SIGMA CONTROL service manual.

Pre–condition: Maintenance task completed.

Service message reset.
Activate password level 4.

. Select the appropriate entry from the maintenance menu.

. Select ’reset’ and ’y’ and confirm with the enter key.

10 --- 48
 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
Filter mat maintenance. 10.3 / 10.4
Every 500 hours Drive belt maintenance 10.7
Every 1000 hours Oil and air cooler maintenance 10.3
Up to 3000 hours Air filter maintenance 10.5
Up to 3000 hours Replace the oil separator cartridge 10.13
at least every
3 years
Up to 6000 hours Oil filter replacement 10.12
at least annually
Up to 12000 hours Drive belt replacement 10.7.2
at least every
3 years
Variable (see Cooling oil change 10.11
table 25)
Annually Check that all electrical connections are tight.
Check the pressure relief valve. 10.8
Have KAESER service check the overheating shut-
down function.
Check the oil and air coolers for leaks. 10.3
Tab. 24 Regular maintenance tasks

10 --- 49
 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 25for future reference.

Coolant oil -- maximal permissible fluid

temperature change interval in operating hours / years
Favourable operating Unfavourable
conditions* operating conditions
SIGMA FLUID PLUS / S---460 3 000 / 1 2 000 / 1
SIGMA FLUID FGL 3 000 / 1 2 000 / 1
SIGMA FLUID FGH 3 000 / 1 2 000 / 1
more than 6 000ser- less than 6 000 ser-
vicehours per year vice hours per year
SIGMA FLUID MOL ±80˚C 3 000 / 1 1 500 / 1
SIGMA FLUID MOL >80˚C 2 000 / 1 1 000 / 1

* Cool to moderate ambient temperatures, low humidity, high duty cycle

Tab. 25 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 12000 hours Check valves.
Up to 12000 hours, Change the drive motor bearings.
at the latest every 3
years
Up to 36000 hours, Change the hose lines.
at the latest every 8
years
Tab. 26 Regular service work intervals

10 --- 50
 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. 18 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.

10 --- 51
 Maintenance

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.

10.4 Filter Mat Maintenance (control cabinet)

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

Pre–condition: Machine switched off.

Supply disconnecting device switched off and locked out.
Machine cooled down.

Fig. 19 Control cabinet ventilation grill

1 Ventilation grill
2 Filter mat
3 Ventilation grill (if provided)
4 Filter mat (if provided)

Removal
. Carefully remove the ventilation grill and take out the filter mat.
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 --- 52
 Maintenance

10.5 Air Filter Maintenance

Material: Spare part

Pre–condition: Machine switched off.

Supply disconnecting device switched off and locked out.
Machine cooled down.

Do not clean the air filter element.

All sealing surfaces are matched to each other.

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

Fig. 20 Air filter maintenance.

1 Retaining clip
2 Air filter cartridge
3 Casing

Opening the air filter housing

. Release the casing retaining clips (1), detach the casing (3) and and lift out the filter
element (2).
Closing the air 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 --- 53
 Maintenance

10.6 Electric Motor Maintenance

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

10.7 Drive Belt Maintenance

10.7.1 Check the belts and their tension.

Machine switched off.
Mains disconnect locked out.
Machine cooled down.

Fig. 21 Re ---tension the belts

1 Tensioning nut
2 Locking nut
3 Marker pin (illustration shows the need for belt re ---tensioning)

Check for damage

. Turn the pulley by hand so that all of the belt can be inspected for damage.
. Change any damaged belts immediately.
Check belt tension.

Check belt tension on initial start ---up and after 24 operating hours.

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 end of the elongated
hole.
Re-- tension the belts
. Loosen the nut (2).
. Use the adjusting nut (1) to adjust spring tension until the marker pin (3) reaches the
lower end of the elongated hole.
. Re---tighten the locking nut (2).

10 --- 54
 Maintenance

10.7.2 Changing the belts

Fig. 22 Belt changing

1 Tensioning nut 5 Insulation
2 Locking nut 6 Bracket
3 Marking pin 7 Plate
4 Plate

. Loosen the nut (2).

. Turn the adjusting nut (1) to loosen the tension on the belts until they can be removed
from the pulley.
. Remove the panel (4) and the insulation piece (5).
. Remove the plate (7) and the bracket (6).
. Remove the belts, drawing them carefully over the fan wheel, and replace with a new
set of belts.
. Replace the bracket (6) the plate (7) and insulating piece (5).
. Use the adjusting nut (1) to adjust spring tension until the marker pin (3) reaches the
lower end of the elongated hole.
. Re---tighten the locking nut (2).
. Close all access doors and replace all cover panels.
. Check tension after the new belts have been in operation for 24---hours.

10.8 Checking the pressure relief valve.

Pre–condition: Machine switched off.
Activate password level 4.

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

Pressure relief valve blows off.

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.
. Abort the test if the working pressure reaches 10% above the blowoff
pressure of the valve.

10 --- 55
 Maintenance

Carry out the test exactly as described in the SIGMA CONTROL manual.

Blowoff protection and system pressure monitoring are switched off during
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 blowoff pressure on the valve. (the blow ---off pressure is usually to be found
at the end of the part identification)
. Observe the pressure indicator on the SIGMA controller and call up the test function.
. Stop the test as soon as the pressure relief valve blows off or working pressure re-
aches 10% above the blowoff set point.
. If necessary, vent the machine and replace the pressure relief valve.
. Deactivate the test function.
. Open the user’s shut ---off valve between the machine and the air main.

10.9 Manually Venting the Machine

Pre–condition: Machine switched off.
Supply disconnecting device switched off and locked out.
Machine cooled down.

Compressed air can cause injury or death.

WARNING Compressed air and devices under pressure can injure or cause death if
the contained energy of the air is released suddenly or uncontrolled.
After shutting down the compressor and venting the oil separator tank
there is still pressure on the check valve from the air main.
. Close the shut ---off valve provided by the user to isolate the machine
from the air main.
. Vent the oil separator tank.
. Vent the air aftercooler to completely depressurise the system between
the user’s shut ---off valve and the minimum pressure/check valve.

Escaping oil mist is damaging to health.

CAUTION . Do not direct the maintenance hose at a person while venting.

. Do not inhale oil mist or vapour.
. Avoid contact with skin and eyes.
Before undertaking any maintenance or service work on the pressure system the machine
must be isolated from the air system and completely vented.
The machine is vented in three stages:
D the oil circuit vents automatically when the machine is switched off,
D air is vented manually from the oil separator tank,
D air is vented manually from the air cooler.

10 --- 56
 Maintenance

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. 23 Venting 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)

. 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 coupling (3).
. Open the shut ---off valve (7) slowly to release pressure.
. Withdraw the male hose fitting and close the shut ---off valve.

Manually venting the compressed air cooler

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

10 --- 57
 Maintenance

10.10 Checking and Topping Up the Cooling Oil

10.10.1 Checking cooling oil level

Pre–condition: Machine cabinet closed.

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

Fig. 24 Check the cooling oil level

max Oil levelmaximum
OK Oil level optimum
min Oil level minimum

The oil level can be seen through the window in the front access door while the machine is
running.
The ideal situation is with the oil level around the optimum mark when the machine is run-
ning.

Operating state Oil level minimum Oil level maximum

LOAD

Tab. 27 Check the cooling oil level

. Check the oil level with the machine running under LOAD.
As soon as the minimum level is reached
. Top up the cooling oil.

10.10.2 Topping up the cooling oil

Material: Cooling oil

Pre–condition: Machine switched off.

Supply disconnecting device switched off and locked out.
Machine cooled down.

Danger of explosion from oils and lubricants!

WARNING Danger of explosion from ignition of oil mist and vapours!

. Fire, naked flame and smoking are forbidden!

10 --- 58
 Maintenance

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. 25 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.
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 coupling (3).
. Open the shut ---off valve (7) slowly to release pressure.
. Withdraw the male hose fitting and close the shut ---off valve.
Manually venting the compressed air cooler
. With the shut---off valve closed, insert the male hose fitting (6) into the hose coupling (1).
. Open the shut ---off valve (7) slowly to release pressure.
. Withdraw the male hose fitting and close the shut ---off valve.

10 --- 59
 Maintenance

Topping up the cooling oil

Fill cooling oil up to the maximum level (see Fig. 24).

Too much cooling oil is detrimental to the function of the oil separator car-
tridge and can lead to an increased oil content in the compressed air.

. 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 Changing the Cooling Oil

Material: Cooling oil
Oil catchment 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 burns from hot components and oil.

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

10 --- 60
 Maintenance

Fig. 26 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 air can be used.
External air is necessary if the machine
D is not operational
D is to be restarted after a long standstill period.
Changing the oil 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 supply disconnecting device.
. Wait at least two minutes for oil to flow back to the separator tank.
Changing the oil with help from an external pressure source
Pre–condition: Machine switched off.
Supply disconnecting device switched off and locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
External source of compressed air available.

10 --- 61
 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 an oil container ready.

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

Fig. 27 Changing the cooling oil, oil cooler

1 Oil cooler 6 Male hose coupling/fitting

2 Hose coupling (oil drain) 7 Shut ---off valve
3 Shut ---off valve

. Have an oil container ready.

. With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling
(2).
. Place the end of the maintenance hose in the oil container and secure it in place.
. Open the shut ---off valve (3).

10 --- 62
 Maintenance

. Open the shut ---off valve (7) slowly and allow oil and air to drain completely.
. Check that the oil separator tank pressure gauge reads zero.
. Close the shut ---off valve (2) and unplug the hose.
Filling with cooling oil
. Open the oil filler plug (4, Fig. 26) 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 on the machine.
. After about ten minutes, check the oil level and top up again, if necessary.
. Switch machine off and check for leaks.

10.12 Oil Filter Maintenance

Material: Spare part
Oil catchment container

Pre–condition: Machine switched off.

Supply disconnecting device switched off and locked out.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.

Danger of burns from hot components and oil.

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

. Work carefully.

Fig. 28 Changing the oil filter

1 Oil filter
2 Direction to unscrew

10 --- 63
 Maintenance

Dispose of parts and materials contaminated with oil in accordance with

environmental 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.

. Turn the oil filter 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 on the machine.
. After about five minutes, check the oil level and top up again, 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:

D contamination in the air drawn into the compressor,
D Compliance with change intervals of
D Cooling oil
D Oil filter
D Air filter

The oil separator element cannot be cleaned.

Dispose of parts and materials contaminated with oil in accordance with

environmental protection regulations.

10 --- 64
 Maintenance

Fig. 29 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 --- 65
 Maintenance

10.14 Logging Maintenance Work

Machine number:
Date Maintenance task carried out Operating hours Signature

Tab. 28 Maintenance log

10 --- 66
 Spares, Operating Materials, 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 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. 29 Machine maintenance parts

11.3 Maintenance Agreement

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

11.4 Service Addresses

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

11 --- 67
 Spares, Operating Materials, Service

11.5 Spare Parts for Service and Repair

Any inspection, maintenance or repair tasks not described in this manual
should be carried out only by an authorised KAESER service agent.

With the help of this parts list you can obtain in advance the spares you need in accord-
ance with your operating conditions.

11 --- 68
 De-commissioning, Storage and Transport

12 De---commissioning, Storage and Transport

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

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

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

Long -- term De-- commissioning

Pre–condition: Before taking out of service the machine should be 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 is 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 --- 71
 De-commissioning, Storage and Transport

12.3 Storage
Pre–condition: The machine must be adequately packed.

Moisture and frost

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

Advice can be obtained from KAESER on suitable storage and initial

start ---up.

Moisture can lead to corrosion, particularly on the surfaces of the airend and oil separator
tank.
Frozen moisture can damage components, diaphragms, valevs and gaskets.

12.4 Transporting

12.4.1 Safety
Transport only by fork truck or lifting cradle and with personnel trained in the safe use of
the transport equipment.
Take weight and centre of gravity into consideration. The centre of gravity is shown in the
drawing in chapter 13.1.3.
Make sure the danger zone is clear.

12.4.2 Fork truck

Pre–condition: The whole machine must be over the forks.

The diagram shows how the machine should be lifted by a fork truck.

Fig. 30 Transport by fork truck

12 --- 72
 De-commissioning, Storage and Transport

12.4.3 Transverse beams

Pre–condition: The lifting cradle complies with local safety regulations.

No pressure bears on the sides of the machine cabinet.

Incorrect application of the lifting cradle can damage the machine.

CAUTION
. Do not attach the lifting cradle to any of the machine components.
. The machine manufacturer can advise on application of a suitable lift-
ing cradle.
Examples of unsuitable fixing points:
D pipe supports
D flanges
D attached components such as centrifugal separators, condensate drains or filters
D rain protection covers
The diagram shows how the machine should be lifted by a cradle.

Fig. 31 Transport with lifting cradle

1 Transverse beams
2 Straps

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

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 --- 73
 Annex

13 Annex

13.1 Diagrams and Drawings

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

13 --- 74
 Appendix

13.1.2 Pipeline and instrument flow diagram (option C1)

13 --- 80
 Appendix

13.1.3 Dimensional Drawing

13 --- 86
 Appendix

13.1.4 Electrical diagram

13 --- 89