SERVICE MANUAL

Screw Compressor
Model: BSD T
No.: 9_5709_00E

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg PO Box 2143 GERMANY Tel. + 49 ---(0)9561 ---6400 Fax + 49 ---(0)9561 ---640130
[Link]
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1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

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

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

2.1 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.3 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.4 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.5 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.6 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.7 Motors and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.7.1 Compressor motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.7.2 Fan 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 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.9.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.9.2 Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.10 Water Cooling (option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.10.1 Design data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.10.2 Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.11 Internal Heat Recovery (option W2 / W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
2.12 Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11

3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12

3.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.3 User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 12
3.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.5 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.5.1 Hazards from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
3.5.2 Hazards from compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14
3.5.3 Hazards from spring forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 14
3.5.4 Further dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.6 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.7 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.7.1 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 15
3.7.2 Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 16
3.7.3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 16
3.8 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 --- 17
4.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.2.1 Machine mountings (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.2.2 Cooling air filter mats (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.2.3 Water cooling (option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.2.4 Heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
4.3 Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.3.1 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.3.2 Tasks of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.3.3 Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
4.3.4 Modulating control (option C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
4.3.5 Refrigeration dryer control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 22
4.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 23
4.5 SIGMA CONTROL Keys and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 24

5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26

5.1 Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26
5.2 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26
5.2.1 Place of installation and space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 26
5.2.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 27
5.2.3 Operating in a compressed air network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 28

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.2 Report any Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.3 Install the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 30
6.5 Condensate Drainage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31
6.6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31
6.6.1 Machine fixing (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31
6.6.2 Water cooling connection (option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 32
6.6.3 Heat recovery system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 32

7 Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34

7.1 Before Initial Start ---up (or Recommissioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34
7.2 Check Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34
7.3 Setting the overload protection cut ---out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34
7.4 Motor Protection Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 35
7.5 Pour Cooling Oil into the Inlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 35
7.6 Checking Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 36
7.7 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 36
7.8 System pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 37

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8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
8.1 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
8.1.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
8.1.2 Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
8.1.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 39
8.2 Switching Off in an Emergency and Switching On Again . . . . . . . . . . . . . . . . . 8 --- 39
8.3 Remote On and Off Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 39
8.4 Switching on and off with the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 40
8.5 Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . . 8 --- 40
8.5.1 Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 41
8.5.2 Resetting warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 41

9 Event Recognition and Fault Rectification . . . . . . . . . . . . . . . . . . . . . . 9 --- 42

9.1 Alarms (machine shut ---down, red LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 42
9.2 Warning Messages (yellow LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.3 Miscellaneous faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 51

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 53
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.2.1 Resetting maintenance interval counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.2.2 Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.2.3 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
10.2.4 Regular service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
10.3 Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
10.3.1 Air cooling (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
10.3.2 Filter mat maintenance (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
10.3.3 Water cooling maintenance (option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
10.4 Internal Heat Recovery Maintenance (option W2 / W3) . . . . . . . . . . . . . . . . . . . 10 --- 59
10.5 Air Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
10.6 Filter mat maintenance (control cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 60
10.7 Electric motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 61
10.8 Checking the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 62
10.9 Checking the Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 63
10.10 Venting the Machine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 64
10.11 Checking and Topping up the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 65
10.11.1 Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 65
10.11.2 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 66
10.12 Changing the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 68
10.13 Oil filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 72
10.14 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 73
10.15 Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 75
10.15.1 Cleaning the refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 75
10.15.2 Testing condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 75
10.15.3 Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 76
10.16 Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 78

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11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79

11.1 Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79
11.2 Ordering Maintenance Parts and Operating Materials . . . . . . . . . . . . . . . . . . . . 11 --- 79
11.3 Maintenance Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79
11.4 Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79
11.5 Spare Parts for Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79

12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . 12 --- 87

12.1 De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 87
12.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 87
12.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 87
12.4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 88
12.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 88

13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
13.1 Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
13.2 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 90
13.2.1 Pipeline and instrument flow diagram (P&I diagrams) . . . . . . . . . . . . . . . . . 13 --- 90
13.2.2 Pipeline and instrument flow diagram (option C1) . . . . . . . . . . . . . . . . . . . . 13 --- 96
13.2.3 Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 102
13.2.4 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 108

iv
 Directory of Illustrations
Chapter --- page

Fig. 1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

Fig. 2 Air ---cooled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
Fig. 3 Refrigeration dryer and condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
Fig. 4 Machine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
Fig. 5 Cooling air filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
Fig. 6 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20
Fig. 7 Internal heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 21
Fig. 8 SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 24
Fig. 9 SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 25
Fig. 10 Installation recommendation, dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 27
Fig. 11 Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
Fig. 12 Control transformer connections (principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 30
Fig. 13 Electrical connection (principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31
Fig. 14 Condensate drainage, dimensions [mm] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31
Fig. 15 Water cooling connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 32
Fig. 16 Heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 33
Fig. 17 Inlet valve oil filling port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 35
Fig. 18 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 36
Fig. 19 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 38
Fig. 20 Switching off in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 39
Fig. 21 Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . . . . 8 --- 40
Fig. 22 Cleaning the cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57
Fig. 23 Cooler filter mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 58
Fig. 24 Air filter maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 59
Fig. 25 Ventilator grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 61
Fig. 26 Compressor motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 62
Fig. 27 Checking the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 62
Fig. 28 Ventilate the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 65
Fig. 29 Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 66
Fig. 30 Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 67
Fig. 31 Changing the cooling oil, oil separator tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 68
Fig. 32 Changing the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 70
Fig. 33 Changing the cooling oil, airend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 71
Fig. 34 Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 72
Fig. 35 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 73
Fig. 36 Refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 75
Fig. 37 Testing the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 76
Fig. 38 Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 77
Fig. 39 Transport by fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 88
Fig. 40 Transport by lifting cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 --- 88

v
 Table Directory
Chapter --- page

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

Tab. 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 3 Machine weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 4 Machine temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
Tab. 5 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 6 Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 7 Delivery (50 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 8 Delivery (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
Tab. 9 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 10 Compressor motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 11 Fan motor data (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 12 Fan motor data (option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Tab. 13 Recommended cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 14 Cooling oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
Tab. 15 Supply 200V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 16 Supply 230V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 17 Supply 400V/3/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 18 Supply 230V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
Tab. 19 Supply 380V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 20 Supply 440V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 21 Supply 460V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 22 Water cooling design data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 23 Water cooling design data: (10 K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 24 Water cooling design data: (30 K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
Tab. 25 Cooler specification; water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
Tab. 26 Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
Tab. 27 Water Quality Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 10
Tab. 28 General specification of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 10
Tab. 29 Flow rate and heat available (option W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11
Tab. 30 Flow rate and heat available (option W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11
Tab. 31 Refrigeration dryer models: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11
Tab. 32 Refrigeration dryer, compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11
Tab. 33 Refrigeration dryer, refrigeration system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 11
Tab. 34 Inspection schedule for Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 13
Tab. 35 SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 25
Tab. 36 SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 25
Tab. 37 Ventilation (Option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 27
Tab. 38 Ventilation (Option K2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 28
Tab. 39 Checklist, installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 34
Tab. 40 Alarm messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
Tab. 41 Warning messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
Tab. 42 Miscellaneous events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 52
Tab. 43 Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55
Tab. 44 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
Tab. 45 Regular service work intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56
Tab. 46 Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 78
Tab. 47 Machine maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 79

vi
 Regarding this Document

1 Regarding this Document

1.1 Handling the Document

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

1.2 Further Documents

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


certificate of acceptance / operating instructions for the pressure vessel


manufacturer’s declaration or declaration of conformity in accordance with applicable
directives


SIGMA CONTROL Service Manual
Make sure all documents are to hand and their contents understood.
Request the supply of any missing documents from KAESER.
Make sure you give the data from the nameplate.

1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the
documentation should be referred to KAESER. Correct use of information will be fully sup-
ported.

1.4 Symbols and Identifications

1.4.1 Warning notices

Here is a notice warning of danger.

DANGER Here are consequences of ignoring the warning notice.

The word ’Danger’ indicates that death or severe injury can result from ig-
noring the notice.
Always read and diligently comply with warning notices.
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the
danger symbol.

Signal word Meaning Consequences of ignoring the warning

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

1 --- 1
 Regarding this Document

1.4.2 Miscellaneous notices and symbols

Here is a task to be carried out.

This symbol identifies environmental protection measures.

This indicates important information.

1 --- 2
 Technical Specification

2 Technical specification
The model designation and important technical information is to be found on the machine
nameplate. The nameplate is found inside the machine. It is fixed to the outside of the con-
trol cabinet or inside the cabinet door.
Please transfer data from the nameplate.
Model
Material (part) no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature
Tab. 1 Nameplate
A list of the options fitted helps to relate the information in this service manual to your ma-
chine.
Please enter details of the options here:
Option Code Exists
Air cooling K1
Water cooling K2
Cooling air filter mat K3
Machine mountings H1
Prepared for heat recovery W1
Internal heat recovery T= 25K W2
Internal heat recovery T= 55K W3
Modulating control C1
Transformer power supply for refrigeration T2
dryer
Tab. 2 Options

2.1 Weight
Maximum weights are shown. Actual weights of individual machines are dependent on
equipment fitted.
BSD 62 BSD 72 BSD 81
Weight [kg] 1260 1325 1410
Tab. 3 Machine weights

2.2 Temperature
BSD 62 BSD 72 BSD 81
Minimum cut ---in temperature [˚ C] 3 3 3
Typical airend discharge temperature 75 --- 100 75 --- 100 75 --- 100
during operation [˚ C]
Max. airend discharge temp. (auto- 110 110 110
matic shut ---down) [˚ C]
Tab. 4 Machine temperatures

2 --- 3
 Technical Specification

2.3 Ambient Conditions

BSD 62 BSD 72 BSD 81
Maximum elevation above sea level* 1000 1000 1000
[m]
Ambient temperature [˚ C] 3 – 45 3 – 45 3 – 45
Inlet air / cooling air temperature 3 – 45 3 – 45 3 – 45
[˚ C]
Maximum relative inlet air humidity at 100 100 100
31 ˚ C [%]
Maximum relative inlet air humidity at 50 50 50
45 ˚ C [%]
* Higher elevation permissible only after consultation with the manufacturer
Tab. 5 Ambient Conditions

2.4 Pressure
See nameplate for maximum working pressure
Blow--- off setting of the pressure relief valve [bar]

Maximum working pressure [bar] BSD 62 BSD 72 BSD 81

8 11.5 11.5 11.5
8.5 11.5 11.5 11.5
11 14 14 14
12 16 16 16
15 --- 16 16
Tab. 6 Pressure relief valve setting

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

Maximum working pressure [bar] BSD 62 BSD 72 BSD 81

8 5.6 7.0 8.2
11 4.4 5.6 6.8
15 3.6 4.4 5.3
Tab. 7 Delivery (50 Hz)

Delivery [m3/min] (60 Hz):

Maximum working pressure [bar] BSD 62 BSD 72 BSD 81

8.5 5.5 6.7 8.3
12 4.6 5.4 6.5
15 --- 4.5 5.3
Tab. 8 Delivery (60 Hz)

2.6 Sound Pressure Level

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

2 --- 4
 Technical Specification

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

BSD 62 BSD 72 BSD 81

Sound pressure level (50Hz) [dB(A)] 68 68 70
Sound pressure level (60Hz) [dB(A)] 69 69 71
Tab. 9 Sound Pressure Level

2.7 Motors and Performance

2.7.1 Compressor motor

BSD 62 BSD 72 BSD 81

Rated power [kW] 30 37 45
Rated speed [rpm] (50 Hz) 2960 2960 2965
Rated speed [rpm] (60 Hz) 3565 3565 3570
Enclosure protection IP 55 IP 55 IP 55
Motor bearing greasing 2000 2000 2000
[operating hours]
Grease requirement, each bearing
[g]*
* Transfer data from motor nameplate to the table
Tab. 10 Compressor motor data

2.7.2 Fan Motor

Air cooling (option K1)

BSD 62 BSD 72 BSD 81

Rated power [kW] 0.75 0.75 0.75
Rated speed [rpm] (50 Hz) 930 930 930
Rated speed [rpm] (60 Hz) 1120 1120 1120
Enclosure protection IP 54 IP 54 IP 54
Tab. 11 Fan motor data (option K1)

Water cooling (option K2)

BSD 62 BSD 72 BSD 81

Rated power [kW] 0.12 0.12 0.12
Rated speed [rpm] (50 Hz) 2500 2500 2500
Rated speed [rpm] (60 Hz) 2700 2700 2700
Enclosure protection IP 54 IP 54 IP 54
Tab. 12 Fan motor data (option K2)

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.

2 --- 5
 Technical Specification

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)
Pour point ---39 ˚ C ---33 ˚ C —
(ISO 3016) / (ISO 3016)
---46 ˚ C
(D 97; ASTM test)
Demulsibility at 30 min — —
54 ˚ C (ISO 6614) /
40/40/0/10 min
(D1401; ASTM---Test)
Tab. 13 Recommended cooling oil

2.8.2 Cooling oil quantity

BSD 62 BSD 72 BSD 81

Total charge [l] (option K1) 26.0 26.0 26.0
Total charge [l] (option K2) 20.0 20.0 20.0
Top ---up volume [l] 4.0 4.0 4.0
(minimum --- maximum)
Additional volume [l] (option W2) 4.0 4.0 4.0
Additional volume [l] (option W3) 1.5 1.5 1.5
Additional volume [l] (option W1) *
* Input the additional volume corresponding to your heat recovery system.
Tab. 14 Cooling oil volume

2 --- 6
 Technical Specification

2.9 Power supply

See electrical diagrams in chapter 13.2.4.

2.9.1 Power supply

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

2.9.2 Power supply specifications

The following conductor cross---sections (multicore Cu) and fusing (HRC fuse slow blow)
are given according to VDE 0100, parts 430 and 523, for ambient temperatures of 30 ˚ C,
non ---standard cable laying C. If other local conditions prevail (high temperature, non ---
standard cable laying or cable lengths above > 50 m) the cross---section should be
checked and adjusted accordingly.
Rated power supply 200V 10%, 3 --- ph, 50Hz

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 160 200 ---
Supply [mm2] 4x70 4x95 ---
Consumption [A] 128 153 --
Tab. 15 Supply 200V/3/50Hz

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 125 160 ---
Supply [mm2] 4x50 4x70 ---
Consumption [A] 110 132 ---
Tab. 16 Supply 230V/3/50Hz

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 80 100 125
Supply [mm2] 4x25 4x35 4x50
Consumption [A] 64 77 94
Tab. 17 Supply 400V/3/50Hz

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 125 160 ---
Supply [mm2] 4x50 4x70 ---
Consumption [A] 113 136 ---
Tab. 18 Supply 230V/3/60Hz

2 --- 7
 Technical Specification

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 80 100 125
Supply [mm2] 4x25 4x35 4x50
Consumption [A] 70 84 104
Tab. 19 Supply 380V/3/60Hz

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 80 100 100
Supply [mm2] 4x25 4x35 4x35
Consumption [A] 61 73 89
Tab. 20 Supply 440V/3/60Hz

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

BSD 62 BSD 72 BSD 81

Pre---fuse [A] 80 80 100
Supply [mm2] 4x25 4x25 4x35
Consumption [A] 58 70 85
Tab. 21 Supply 460V/3/60Hz

2.10 Water Cooling (option K2)

2.10.1 Design data

BSD 62 BSD 72 BSD 81

Max. permissible discharge temp. [ 70 70 70
˚ C]
Tab. 22 Water cooling design data

Cooling water temperature rise 10 K

BSD 62 BSD 72 BSD 81

Max. permissible inlet temp. [ ˚ C] 40 40 40
Cooling water volume [m3/h] 2.9 3.6 4.4
Water pressure drop [bar] 0.7 1.1 1.7


Tab. 23 Water cooling design data: 10 K)

Cooling water temperature rise 30 K

BSD 62 BSD 72 BSD 81

Max. permissible inlet temperature 20 20 20
[  C]
Cooling water volume [m3/h] 1.0 1.2 1.5
Water pressure drop [bar] 0.5 0.5 0.5


Tab. 24 Water cooling design data: 30 K)

2 --- 8
 Technical Specification

Cooler specification

Material of manufacture 1.4401

Solder Copper
Maximum working pressure (cooling 10
water end) [bar]
Unsuitable cooling medium Seawater
Consult Kaeser before using cooling water sol-
utions
Tab. 25 Cooler specification; water cooling

2.10.2 Cooling Water Quality

Do not use the cooling water as drinking water.

If a leak occurs, oil can contaminate the cooling water.

It is imperative that measures for cooling water treatment and filtration are carried out.
The addresses of companies specialising in cooling water analysis and the supply of suit-
able equipment for its treatment can be obtained from KAESER.
To avoid operational breakdowns caused by a corroded or clogged cooler, the cooling
water must meet the following requirements:

pH value 7.5 to 9
Hardness [ dH] 4,0 ---8,5
Chloride (Cl) [mg/l] < 150
Free chlorine gas (Cl2) [mg/l] < 1
Sulphate (SO3) [mg/l] < 1
Dissolved iron (Fe) [mg/l] < 0.2
Hydrogen carbonate (HCO3) [mg/l] 70 ---300
Sulphate (SO4) [mg/l] < 70
HCO3 / SO4 > 1
Electrical conductivity [ S/cm] 10 ---500
Ammonia (NH3) [mg/l] < 2
Dissolved magnesium (Mn) [mg/l] < 0,1
Dissolved aluminium (Al) [mg/l] < 0,2
Nitrate (NO3), dissolved [mg/l] < 100
Hydrogen sulphate (SO2) [mg/l] < 0,05
Free aggressive carbon dioxide (CO2) [mg/l] < 5
Glycol [%] < 50
Solids (particle size) [mm] < 0,1
Algae not allowed
Tab. 26 Cooling Water Quality

2.11 Internal Heat Recovery (option W2 / W3)

A plate heat exchanger is installed for heat recovery.
Generally water is used as the heat transfer medium. This must conform to the specifica-
tion given below.

2 --- 9
 Technical Specification

The water may not be used as drinking water.

If a leak occurs, oil can contaminate the cooling water.

The manufacturer should be consulted before another type of heat transfer

medium is used.

Water Quality Specification

pH value 7.5 to 9
Hardness [ ˚ dH] 4.,0 ---8.5
Chloride (Cl)* [mg/l] < 150
Free chlorine gas (Cl2) [mg/l] < 1
Sulphate (SO3) [mg/l] < 1
Dissolved iron (Fe) [mg/l] < 0.2
Hydrogen carbonate (HCO3) [mg/l] 70 ---300
Sulphate (SO4) [mg/l] < 70
HCO3 / SO4 > 1
Electrical conductivity [ms/cm] 10 ---500
Ammonia (NH3) [mg/l] < 2
Dissolved magnesium (Mn) [mg/l] < 0.1
Dissolved aluminium (Al) [mg/l] < 0.2
Nitrate (NO3), dissolved [mg/l] < 100
Hydrogen sulphate (SO2) [mg/l] < 0.05
Free aggressive carbon dioxide (CO2) [mg/l] < 5
Glycol [%] < 50
Solids (particle size) [mm] < 0.1
Algae not allowed
Tab. 27 Water Quality Specification

If the heat transfer medium outlet temperature is to be kept constant, the

user must install an appropriate regulating device.

Heat Exchanger Specification

BSD 62 BSD 72 BSD 81

Maximum working pressure of the 10 10 10
heat transfer medium [bar]
Pressure drop [bar] < 0.5 < 0.5 < 0.5
Plate material 1.4401 1.4401 1.4401
Solder Cu Cu Cu
Maximum permissible temperature of 100 100 100
the heat transfer medium [˚ C]
Tab. 28 General specification of the heat exchanger

Flow rate and heat capacity by heating from 45˚ C to 70˚ C (equivalent to DT = 25K),
(option W2)

BSD 62 BSD 72 BSD 81

Flow rate [m3/h] 0.9 1.1 1.4
Max. heat capacity available [kW] 26.8 33.1 40.9

2 --- 10
 Technical Specification

BSD 62 BSD 72 BSD 81

Max. heat capacity available [MJ/h] 96 119 147
Max. heat capacity available [kcal/h] 23044 28478 35082
Tab. 29 Flow rate and heat available (option W2)

Flow rate and heat capacity by heating from 15˚ C to 70˚ C (equivalent to DT = 55K),
(option W3)

BSD 62 BSD 72 BSD 81

Flow rate [m3//h] 0.4 0.5 0.6
Max. heat capacity available [kW] 26.8 33.1 40.9
Max. heat capacity available [MJ/h] 96 119 147
Max. heat capacity available [kcal/h] 23044 28478 35082
Tab. 30 Flow rate and heat available (option W3)

2.12 Refrigeration Dryer

Model

BSD 62 BSD 72 BSD 81

Dryer type ABT 72 ABT 72 ABT 81
Tab. 31 Refrigeration dryer models:

Compressed Air System

ABT 72 ABT 81
Pressure drop [bar] 0.2 0.2
(in relation to 7 bar working pressure)
Maximum permitted working pres- 16 16
sure [bar]
Tab. 32 Refrigeration dryer, compressed air system

Refrigeration System

ABT 72 ABT 81
Refrigerant R 134a R 134a
Maximum charge [kg] 2.2 2.5
Maximum permitted working pres- 21 21
sure [bar]
Safety pressure switch set point 21 21
[bar]
Fan pressure switch cut ---in setting 7.5 7.5
[bar]
Fan pressure switch cut ---out setting 7 7
[bar]
Tab. 33 Refrigeration dryer, refrigeration system

2 --- 11
 Safety and Responsibility

3 Safety and Responsibility

Disregarding this notice can result in serious injury!

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

3.1 Correct Use

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

3.2 Incorrect Use

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

3.3 User’s Responsibilities

Personnel
Allow only specialists or persons who have been trained or instructed on this machine to
carry out work on the machine. This applies particularly for:
installation and initial start ---up,
maintenance and service work,
repairs,
inspections.
Allow work to be carried out on electrical equipment only by a qualified electrician or
trained personnel under the supervision of a qualified electrician, and according to electri-
cal engineering regulations.
Ensure that all persons working on the machine have read, understood and observe the
safety ---relevant passages in the service manual.
Give clear instructions on reporting faults and damage to the machine.
Observe the relevant regulations during installation, operation, maintenance and repair of
the machine. These are, for example, nationally applied European directives and/or valid
national laws and safety and accident prevention regulations.
Adhere to inspection schedules and accident prevention regulations
The machine is subject to local inspection schedules.

3 --- 12
 Safety and Responsibility

Operation in Germany:
Recurring inspections in accordance with VBG 16 --- § 18
The company (user) must ensure that recurring inspections of safety devices on com-
pressors with motor power greater than 0.5 kW are carried out by qualified persons.
Inspection intervals of one year are generally sufficient.
Oil change in accordance with VBG16 --- §17
Oil change as required but at least once a year. The oil need not be changed if analysis
shows it to be still useable.
Inspection schedule in accordance with operating safety regulations and with the
strictest according to §15.
Inspection Schedule Inspecting authority
Installation and equip- before initial start ---up approved supervisory board
ping
Internal inspection every 5 years after installation or qualified persons
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. 34 Inspection schedule for Germany

3.4 Safety Devices

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

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

3.5.1 Hazards from electric current

Electric shock can kill!

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


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


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


Check that no voltage is present.


Do not work on electrical components unless they are voltage---free.


Work carefully.


Before switching on again ensure that
no one is working on the machine,
all panels are in place and secured,
all access doors are closed.

3 --- 13
 Safety and Responsibility

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

3.5.2 Hazards from compressed air

Hazards from compressed air quality
The compressed air from this machine may not be used without taking appropriate precau-
tions:
as breathing air
for processing foodstuffs

Unsuitably treated compressed air can cause injury or death.

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

Poisoning of foodstuffs when they are processed using unsuitable com-
pressed air.


Never inhale compressed air.


Use appropriate systems for compressed air treatment before using
the compressed air from this machine as breathing air and/or for the
processing of foodstuffs.


Use foodstuff---compatible cooling oil a whenever compressed air is to
come into contact with foodstuffs.

Hazards from compressive forces

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

Serious injury or death from released compressive forces.

WARNING Serious injury or death can result from loosening or opening components
under pressure.


Close shut ---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the ma-
chine.


De---pressurize all pressurized components and enclosures.


Check all machine hose connectors with a hand ---held pressure gauge
to ensure that all read zero .

Extension or modification of the compressed air supply system

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

3.5.3 Hazards from spring forces

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

3 --- 14
 Safety and Responsibility

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

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

3.5.4 Further dangers

Handling cooling and lubricating fluids


Avoid contact with skin and eyes.


Do not inhale oil mist or vapour.


Do not eat or drink while handling cooling and lubricating fluids.


Fire, open flame and smoking are strictly forbidden.
Welding
When welding is taking place on or near the machine take adequate measures to ensure
that no parts of the machine or any oil vapours can ignite because of sparks or heat.
Spare parts
The use of unsuitable parts may adversely influence the safe working of the machine.
Use only genuine KAESER spares for parts subject to pressure.
Handling refrigerant
Leaking refrigerant can cause frostbite.


Use appropriate equipment for pumping out refrigerant.


Avoid contact with skin and eyes.


Do not inhale.

3.6 Warning Symbols

Beware of life---threatening electrical voltage.
Do not touch electrical components; danger of electric shock.
Before opening, switch off at the main switch and lock off to secure against
unwanted or accidental switching on.
Warning of hot surface.
Do not touch surface --- danger of burning.
Wear long ---arm garments (not synthetics such as polyester) and protective
gloves.
Beware --- machine starts automatically.
Machine can start automatically or by remote start command.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.

3.7 Emergencies
3.7.1 Fire fighting
Suitable extinguishing media:


foam


powder


carbon dioxide


sand or earth

3 --- 15
 Safety and Responsibility

Unsuitable or unsafe extinguishing media:

powerful water jet

3.7.2 Cooling oil

Skin contact:


wash off immediately

Eye contact:


rinse thoroughly with lukewarm water and seek medical assistance.
If necessary, request a copy of the safety data sheet for KAESER SIGMA FLUID.

3.7.3 Refrigerant

Inhalation:


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

Skin contact:


Wash immediately with plenty of water.
Treat burns and frostbite.

Eye contact:


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

3.8 Environmental Protection

Do not allow cooling oil to escape to the environment or into the sewage
system.

Store and dispose of operating materials and replaced parts in accordance with local envi-
ronment protection regulations. Observe national regulations. This applies particularly to
parts contaminated with cooling oil.

Do not allow refrigerant to escape into the atmosphere.

Give refrigerant only to authorised bodies for disposal.

3 --- 16
 Design and Function

4 Design and Function

4.1 Machine Overview

4.1.1 Cabinet

Fig. 1 Cabinet

1 Control cabinet door

2 Latch
3 Removable panel
The cabinet, when closed, serves various purposes:
Sound damping
Protection
Cooling air flow control
Safe and reliable operation can only be ensured with the cabinet closed.
Latches are released by a key supplied with the machine.
Access doors are hinged to swing open, removable panels must be lifted off.

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

4 --- 17
 Design and Function

Fig. 2 Air ---cooled machine

1 Inlet valve [2] 6 Control cabinet

2 Coupling [5] 7 Oil separator tank [6]
3 Compressor motor [3] 8 Air filter [1]
4 Oil filter [10] 9 Oil/air cooler [11/13]
5 Airend [4] 10 Add ---on cabinet for frequency converter /
refrigeration dryer

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

4 --- 18
 Design and Function

Refrigeration Dryer

Fig. 3 Refrigeration dryer and condensate drain

10 Refrigeration Dryer
11 Centrifugal separator
12 Condensate drain

The centrifugal separator (11) removes precipitate from the air.

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

4 --- 19
 Design and Function

4.2 Options

4.2.1 Machine mountings (option H1)

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

Fig. 4 Machine mountings

4.2.2 Cooling air filter mats (option K3)

Mats filter the cooling air and keep the cooler surface clean.

Fig. 5 Cooling air filter mats

1 Cooling air filter mat

4.2.3 Water cooling (option K2)

Plate heat exchangers in stainless steel are used for water ---cooled machines.

Fig. 6 Water cooling

1 Oil cooler [11] 3 Cooling water connection
2 Compressed air aftercooler [13] 4 Cooling water connection

4.2.4 Heat recovery

Prepared for external heat recovery (option W1)
Connections are provided and bridged.

4 --- 20
 Design and Function

An external heat recovery system can be retro ---fitted at any time.

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

Fig. 7 Internal heat recovery

1 Plate heat exchanger [26]

4.3 Operating States and Control Modes

4.3.1 Operating states

There are three operating states:
LOAD: the inlet valve is open. The airend delivers compressed air to the system.
The compressor motor runs under full load.
IDLING: The inlet valve is closed. The minimum pressure/check valve shuts off the oil
separator from the air system. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the
airend and back to the inlet valve via the venting valve.
The compressor motor runs without load and draws little current.
STANDSTILL: The inlet valve is closed. The minimum pressure/check valve shuts off
the oil separator from the air system. The oil separator tank is vented.
The compresor motor is stopped.
PARTIAL LOAD (option C1): The proportional controller continuously varies the degree
of opening of the inlet valve, and thereby the delivery rate of the compressor, in re-
sponse and in proportion to the air demand. The airend delivers compressed air to the
system.
The load and power consumption of the drive motor rises and falls with the air de-
mand.
The regulating valve is factory set. Consult with KAESER Service before changing.

4.3.2 Tasks of the controller

Using the selected control mode, the controller switches the compressor between its vari-
ous operational states in order to 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.

4.3.3 Control Modes

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

4 --- 21
 Design and Function

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

4.3.5 Refrigeration dryer control modes

The following control modes are available:
CONTINUOUS
TIMER
CONTINUOUS
In this mode the refrigeration dryer runs continuously, even if the compressor is shut down.
This mode of control is set up at the factory.
TIMER
The refrigeration dryer is time---controlled and is switched on and off when the compressor
is stopped. In this mode, the operating temperature is held within tight limits.
This control mode saves energy.
Which control mode is the most practical, and when?

Control mode Advantage Disadvantage

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

4 --- 22
 Design and Function

4.4 Safety Devices

The following safety devices are provided and may not be changed:
EMERGENCY STOP button
The EMERGENCY STOP button shuts down the compressor immediately. The motor
remains still. The pressure system is vented.
Pressure relief valve
The pressure relief valve protects the system from excessive pressure. This is factory
set.
Housing and covers for moving parts and electrical connections.
Protection from accidental contact.

4 --- 23
 Design and Function

4.5 SIGMA CONTROL Keys and Indicators

Fig. 8 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 --- 24
 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. 35 SIGMA CONTROL keys

Fig. 9 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. 36 SIGMA CONTROL indicators

4 --- 25
 Installation and Operating Conditions

5 Installation and Operating Conditions

5.1 Surroundings
No open flames or sparks at the place of installation.
Ensure that flying sparks or excessive temperatures during welding work on the ma-
chine are not a fire hazard.
The machine is not explosion ---proof.
Do not operate in areas in which specific requirements with regard to explosion
protection are applied.
For instance, the requirements of 94/9/EU (ATEX directive) for correct use in explosion
hazardous areas.
Clean inlet air with no damaging contaminants.
Inlet air free of explosive or chemically unstable gas or vapour.
Inlet air free of acid ---forming substances, particulatly ammmonia, chlorine or hydrosul-
phide.
Keep ambient temperatures within recommended limits.
Keep the airend discharge temperature within limits to prevent build ---up of conden-
sate.
Suitable fire extinguishing material must be to hand.

5.2 Installation Conditions

5.2.1 Place of installation and space required

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

5 --- 26
 Installation and Operating Conditions

Fig. 10 Installation recommendation, dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Inlet air opening

5.2.2 Ventilation
Values given are minimum guidelines.

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

the compressor room.

Ensure that the volume of air flowing into the compressor room is at
least equivalent to that being removed from it by the compressor and
exhaust fan.
Make sure that the machine and exhaust fan can only operate when
the inlet aperture is actually open.

Option K1

BSD 62 BSD 72 BSD 81

Inlet opening [m
] 0.9 1.1 1.4
Extractor for forced ventilating: 13000 15500 19500
Flow rate [m  /h] at 100 Pa
Exhaust air duct: 700 x 700 700 x 700 700 x 700
Dimensions [mm]
Tab. 37 Ventilation (Option K1)

5 --- 27
 Installation and Operating Conditions

Option K2

BSD 62 BSD 72 BSD 81

Inlet opening [m ] 0.3 0.3 0.4
Extractor for forced ventilating: 3600 4000 5500
Flow rate [m /h] at 100 Pa

Exhaust air duct: 700 x 700 700 x 700 700 x 700

Dimensions [mm]
Tab. 38 Ventilation (Option K2)

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

5.2.3 Operating in a compressed air network

When the machine is connected to an air network, the network operating pressure must
not exceed 16 bar.
Initial filling of a fully vented air network generally creates very a high rate of flow through
air treatment devices. These conditions are detrimental to correct air treatment. Air quality
suffers.
To ensure maintenance of desired air quality when filling a vented air main we recommend
the installation of an air main charging system.
KAESER is ready to offer good advice.

5 --- 28
 Installation

6 Installation

6.1 Safety

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

equately treated compressed air is used.
DANGER
Injury and/or poisoning caused by the use of insufficiently treated com-
pressed air as breathing air or for the processing of foodstuffs.
Never use compressed air as breathing air unless it has been suitably
treated, the pressure is appropriately reduced and breathing appar-
atus is used.
Use foodstuff---compatible cooling oil and suitable treatment whenever
compressed air is to come into contact with foodstuffs.

There is considerable danger of injury or death because of spring

forces when spring--- loaded components are incorrectly opened (dis-
WARNING mantled).

Minimum pressure/check valves, pressure relief valves and inlet valves are
heavily spring loaded.
Do not open (dismantle) valves.

All functioning parts are factory set.

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

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

6.2 Report any Transport Damage

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

6.3 Install the Compressed Air Connection

Pre --- condition: air main completely vented.

Fig. 11 Compressed Air Connection

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

6 --- 29
 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 electricity supplier.
Cable core cross---sections and fuse ratings must conform with local regulations (in Ger-
many, for example, DIN VDE 0100, parts 430 and 523).
Check the permissible 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 supply ---disconnecting device.
This could be, for example, a mains power switch with fused supply. If a circuit breaker
is used it must be suitable for the motor starting characteristics.
Before initial start--- up
The control transformer in the control cabinet has connections for varying supply volt-
ages. Check that the correct connections are made for the supply voltage provided for
the machine. If necessary, re---connect the transformer using the
5% taps to match
the supply voltage. (see Fig. 12 and chapter 13.2.4)
1 3
1

1 3
1 4

2
1

1 3

2
Fig. 12 Control transformer connections (principle)
1 Primary
2 Secondary
3 Mains supply
4 Bridge between terminals

6 --- 30
 Installation

Connect the machine to the mains power supply in accordance with fig. 13 and the
electrical diagram in chapter 13.2.4.

Fig. 13 Electrical connection (principle)

1 User’s main switch and fusing

6.5 Condensate Drainage Connection

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

Collect condensate in a suitable container and dispose of in accordance

with environmental regulations.

Condensate drainage connection

Fig. 14 Condensate drainage, dimensions [mm]

1 Drain hose
2 Condensate collecting line

6.6 Options

6.6.1 Machine fixing (option H1)

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

6 --- 31
 Installation

Use appropriate bolts to anchor the machine.

6.6.2 Water cooling connection (option K2)

The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the
cooling water connection ports.
Use connecting lines made of the appropriate material for the water system. Take into ac-
count the effect of electro ---chemical reaction.
Keep the effect of pressure surge on the cooler as low as possible.
Where pressure surges are unavoidable provide an expansion tank to damp pulsations.

Fig. 15 Water cooling connection

A Cooling water outlet 10 Shut ---off valve
B Cooling water inlet 12 Connection port with stopper
17 Pressure relief valve
The user is to provide the following fittings:


Dirt trap with max. 0.1 mm strainer mesh.


Shut ---off valves (10) and connection ports (12) for maintenance and venting.


Pressure relief valve (17) prevents build ---up of excessive pressure.

Blowoff pressure and capacity are related to the user’s installation design.
Keep to the cooler technical specification.

Connect the cooling water line to the fitting.

Open the shut ---off valve on the cooling water outlet (A).
Slowly open the cooling water inlet shut ---off valve (B) to gradually fill the cooler with
water.
Vent the water lines.

6.6.3 Heat recovery system connection

[Link] Internal heat recovery (option W2, W3)

The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the
connection ports.
Use connecting lines of suitable material. Take into account the effect of electro ---chemical
reaction.

6 --- 32
 Installation

Keep the effect of pressure surge on the heat exchanger as low as possible.
Where pressure surges are unavoidable provide an expansion tank as a damper.

Fig. 16 Heat recovery

A Outlet 10 Shut ---off valve

B Inlet 12 Connection port with stopper
17 Pressure relief valve
The user is to provide the following fittings:
Dirt trap with max. 0.1 mm strainer mesh.
Shut ---off valves (10) and connection ports (12) for maintenance and venting.
Pressure relief valve (17) on the inlet (B) prevents build ---up of excessive pressure.

Blowoff pressure and capacity are related to the user’s installation design.
Keep to the heat exchanger technical specification.


Connect the water lines to the fittings.


Open the shut ---off valve on the outlet (A).


Slowly open the inlet (B) shut ---off tap to gradually fill the heat exchanger with water.


Vent the lines.

[Link] External heat recovery system (option W1)

The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the
connection ports.


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

6 --- 33
 Initial Start--- up

7 Initial Start---up

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

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

Storage period longer Action

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

7.2 Check Installation and Operating Conditions

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

Check Chapter Done?

1 All installation conditions fulfilled? 5
2 User’s lockable supply disconnecting device installed? 6.4
3 Is the power supply as specified on the nameplate? 2
4 Supply cable section and fuse rating adequate? 2.9.2
5 All electrical connections checked for tightness?
6 Shut ---off valve fitted to compressed air outlet? 6.3
7 Connection made to air main with hose or axial compen- 6.3
sator?
8 Sufficient cooling oil in the oil separator tank?
(cooling oil indicator outside the red zone?)
9 Required quantity of cooling oil poured into the inlet port? 7.5
10 Motor protection relay set correctly with regard to the 7.4
power supply?
11 Operators full conversant with safety regulations?
12 Supply of cooling water ensured? 6.6.2
(option K2)
13 Machine anchored to the floor? 6.6.1
(option H1)
14 All access doors closed and latched and all removable 4.1.1
panels in place and secured?
Tab. 39 Checklist, installation conditions

7.3 Setting the overload protection cut---out

Compressor motor
In the star ---delta configuration the phase current is fed via the overload protection cut ---
out. This phase current is 0.58 times the rated machine current (see nameplate in the con-
trol cabinet).

7 --- 34
 Initial Start--- up

Setting
The standard setting is made at the factory.
To prevent the overload protection cutout from being triggered by voltage fluctuations, tem-
perature influences or component tolerances, the setting can be higher than the arithmeti-
cal phase current.

7.4 Motor Protection Switch Setting

Fan motor
In direct on ---line start the starting current is fed via the motor overload protection switch.
Setting
The standard setting is made at the factory.
To prevent the overload protection switch from being triggered by voltage fluctuations, tem-
perature influences or component tolerances, the setting can be higher than the motor
rated current (see motor nameplate).

7.5 Pour Cooling Oil into the Inlet Port

Material: 1 l cooling oil

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. 17 Inlet valve oil filling port

1 Screw plug
2 Inlet valve
Remove the plug (1) from the inlet valve (2).
Pour cooling oil into the airend.

7 --- 35
 Initial Start--- up

Fig. 18 Coupling

1 Compressor block 3 Cover

2 Coupling 4 Rotational direction arrow
Remove the cover (3).
Note the rotational direction arrow (4).
Grasp the coupling (2) and turn it and the airend shaft (1).
Replace the coupling cover (3).

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.

7.7 Initial Start---up

Open the shut ---off valve to the air network.
Switch on at the main supply isolator.
The controller makes a self---test and the green LED ’Power ON’ lights.
Press the ’Operating state LOAD/IDLE’ key.
Press the ’ON’ key.
The green LED ’Machine ON’ lights.
Allow the machine to idle for at least one minute.
This ensures good distribution of cooling oil.
Press the ’Operating state LOAD/IDLE’ key.
The machine switches to the LOAD state and delivers compressed air.

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

After the first 50 operating hours carry out the following:

Check that all electrical connections are tight.

7 --- 36
 Initial Start--- up

7.8 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 --- 37
 Operation

8 Operation

Fig. 19 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

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

8.1.1 Switching on

Compressed air can cause serious injury!

WARNING Serious injury possible.

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


no one is working on the machine,


all panels are in place,


all access doors are closed,


no parts of the machine are colder than + 3 ˚ C.
Switch on at the main supply isolator.
The controller makes a self---test and the green LED ’Power ON’ (8) lights.
Press the ’ON’ key (2).
The green LED ’Machine ON’ lights (1).
The compressor motor runs, assuming the network pressure is lower than the cut ---out
pressure.

8.1.2 Automatic restart

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

Automatic restart is factory ---set.

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

8 --- 38
 Operation

8.1.3 Switching off

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

8.2 Switching Off in an Emergency and Switching On Again

Fig. 20 Switching off in an emergency

9 EMERGENCY STOP button

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

Pre --- condition: Fault rectified.

Turn the ’EMERGENCY STOP’ button in the direction of the arrow to unlatch it.
Press the ’Reset’ key (11).
Switch the machine on.

8.3 Remote On and Off Switching

Pre --- condition: Connection to a remote control device.

Press the ’Remote’ key (5).

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

8 --- 39
 Operation

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

Label the remote control device accordingly:

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

8.4 Switching on and off with the Clock

Pre --- condition: Clock programmed

Press the ’Clock’ key (4).

The LED in the corner of the key lights. The integrated clock has control of the machine.

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

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

8.5 Acknowledging and Resetting Warning and Alarm Messages

Fig. 21 Acknowledging and Resetting Warning and Alarm Messages

10 ’Warning’ LED (yellow)

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

Alarm
An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11).
Faults are displayed on the ”New value” principle:

The alarm is triggered LED blinks

Alarm is acknowledged LED illuminates
Alarm delets LED out

8 --- 40
 Operation

or

The alarm is triggered LED blinks

Alarm delets LED blinks
Alarm is acknowledged LED out

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

8.5.1 Resetting alarm messages

Pre --- condition: Fault rectified.

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

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

8.5.2 Resetting warning messages

Pre --- condition: The cause of the warning eliminated.

Maintenance task completed.

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

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

8 --- 41
 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 Alarms (machine shut---down, red LED blinking)

Message Possible cause Action KAESER service
technician only
access doors Door opened during Close the door(s).
machine operation.
ADT Maximum airend di- Clean cooler.
scharge tempera- Machine positioned
ture exceeded. with cooling air out-
let too near a wall.
Check cooling oil le-
vel.
Maintain permitted
room temperature.
Check the cooling
oil level.
Replace oil filter.
ADT dT/dt Maximum airend di- Clean cooler.
scharge tempera- Machine positioned
ture rise rate excee-
with cooling air out-
ded. let too near a wall.
Check cooling oil le-
vel.
Maintain permitted
room temperature.
Check the cooling
oil level.
Replace oil filter.
airend rotation The motor is turning Changeover phase
in the wrong direc- lines L1 and L2.
tion.
AI 1 open cct. Connection is bro- Check line and con- Check the sensor.
ken between the nection.
system pressure
transducer and ana-
log input 1.
Short circuit to
earth.

9 --- 42
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
AI 2 open cct. Connection is bro- Check line and con- Check the sensor.
ken between the in- nection.
ternal pressure
transducer and ana-
log input 2.
Short circuit to
earth.
AI 3 open cct. No connection be- Check line and con- Check the sensor.
tween the sensor nection.
measuring airend di-
scharge tempera-
ture and the analog
input 3.
AI 4 open cct. No connection be- Check line and con- Check the sensor.
tween the sensor nection.
measuring motor
temperature and the
analog input 4.
AI 5 open cct. There is no connec- Check line and con- Check the sensor.
tion between the nection.
sensor allocated to
analog input 5 and
the input itself.
Short circuit to
earth.
AI 6 open cct. There is no connec- Check line and con- Check the sensor.
tion between the nection.
sensor allocated to
an analog input and
the input itself.
Short circuit to
earth.
...
AI 8 open cct.
AI 1 short cct. The connection be- Check line and con- Replace defective
tween the sensor nection. sensor.
and the analog input
is shorted.
...
AI 8 short cct.
back pressure Back pressure in the Check venting line. Check venting valve.
oil separator tank Check minimum
caused by poor ven-
pressure/check
ting. valve.
blowoff prot. The blowoff pres- Change the oil sepa- Check the minimum
sure of the pressure rator cartridge. pressure/check
relief valve on the oil Open the shut ---off valve, the control
separator tank has valve in the venting valve and the inlet
been exceeded. line. valve.
Check sensor, line
and connection.

9 --- 43
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
condensate drain Fault in condensate Check condensate
drainage. drainage.
coolingwater low Cooling water pres- Check cooling water
sure too low. supply.
Check that cooling
water shut ---off valve
is fully open.
EMERGENCYSTOP EMERGENCY STOP Unlatch the push-
button pressed. button.
ext. message 0 Rectify fault.
...
ext. message 5
Fan M2 I First fan motor shut Investigate cause.
down because of Reset overload trip.
overload.
Fan M3 I Second fan motor Investigate cause.
shut down because Reset overload trip.
of overload.
Fan M4 I Third fan motor shut Investigate cause.
down because of Reset overload trip.
overload.
HT cell Fault in the high ten- Check high tension
sion cell. cell.
mains cont. off? The mains contactor Check auxiliary con-
does not drop out tact block.
despite an OFF
Check power supply
command. for contactor.
mains cont. on? The mains contactor Check auxiliary con-
does not pull in de- tact block on K1M.
spite an ON com- Check power supply
mand. for contactor.
mains monitor Fault in mains power Have the mains po-
supply. wer supply checked.
model Machine model in- Re---enter model
distinct name
Exchange controller
motor I Drive motor shut- Change the oil sepa-
down because of rator cartridge.
overload.
Check minimum
pressure/check
valve.
Investigate cause.
motor T Drive motor over- Ensure adequate
heated. ventilation.
Install an extractor.
Clean the motor.
motor bearings Drive motor bear- Grease the motor Change motor bear-
ings overheated. bearings with the ings.
greasing device.

9 --- 44
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
neutral p ---switch Rectify fault
neutral T---switch Rectify fault
no press. buildup Machine produces Check for air leaks. Check the inlet
no compressed air. Check the coupling / valve.
The setpoint pres- V---belts. Check minimum
sure does not rise pressure/check
above 3.5 bar for a valve.
preset period. Compare the ’inter-
nal pressure’ indica-
ted with the reading
shown on the oil se-
parator tank pres-
sure gauge.
O 0.6/A 0.7 Short circuit in the Check line and con- Check the consu-
line between output nection. mer.
O 0.6 or O 0.7 and a
consumer.
O 1.6/A 1.7 Short circuit in the Check line and con- Check the consu-
line between output nection. mer.
O 1.6 or O 1.7 and a
consumer.
oil p No changeover to Check oil circulation. Replace defective
load as long as the Check pressure switch.
minimum oil pres- switch, line and con-
sure is not reached. nection.
PD temperature

Compressor outlet Check sensor, regu-
temperature too low. lator.
Check the frequency
converter.
PD temperature  Compressor outlet Check the fan motor. Check sensor, regu-
temperature too Clean the cooler. lator.
high. Check the frequency
Check the cooling
oil level. converter.

Power supply

2. Power failure Check power supply
voltage.
Check door inter-
lock.
pRV  The blowoff pres- Replace the pres-
sure of the pressure sure relief valve.
relief valve on the oil
separator tank has
been exceeded.
RD compr. p 
Pressure switch on Ensure adequate Replace defective
the refrigerant ventilation. sensor.
compressor activa-
Clean the refrigerant
ted. condenser.
Clean the cooler.

9 --- 45
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
RD compr. T Refrigerant comp- Clean the refrigerant
ressor overheating. condenser.
Ensure adequate
ventilation.
Install an extractor.
Cleaning the cooler
RD compr. T
Refrigerant comp- Check refrigeration
ressor too cold. dryer.
separator dp  Oil separator cart- Replace the oil se-
ridge clogged. parator cartridge.
separator T  Maximum tempera- Check the cutout Check the cutout on
ture on oil separator line. the oil separator
tank outlet excee- tank outlet.
ded.
SIGMA CONTROL T  SIGMA controller Ensure adequate
housing temperature ventilation.
to high. Ensure permitted
room temperature
not exceeded.
Check control cabi-
net ventilator (filter
mats).
softstart Fault in the soft start Check the soft start
system. system.
start T  Air temperature at Heat the compres- Install auxiliary hea-
the airend discharge sor room. ting.
port too low.
Ambient tempera-
ture below + 3˚ C.
V---belts broken The V---belts parted Replace the
during machine ope- V---belts.
ration.
VFD Frequency converter Check the frequency
faulty. converter.
Tab. 40 Alarm messages and actions

9 --- 46
 Event Recognition and Fault Rectification

9.2 Warning Messages (yellow LED blinking)

Message Possible cause Action KAESER service
technician only
access doors Doors opened dur- Close access doors.
ing machine opera-
tion.
ADT The maximum per- Clean cooler.
missible airend di- Machine positioned
scharge tempera- with cooling air out-
ture will soon be re- let too near a wall.
ached.
Check cooling oil le-
vel.
Maintain permitted
room temperature.
Check cooling oil le-
vel.
Replace the oil filter.
air filter dp The pressure drop Clean/replace the air
across the air filter is filter element.
rising.
Air filter element
clogged.
air filter h
The service interval Clean/replace the air
to the next air filter filter element.
element check has
expired.
Bearing

The service interval Grease the motor
maintenance h to the next bearing bearings.
greasing has expi-
red.
blowoff prot. Warning Change the oil sepa- Check the minimum
The blowoff pres- rator cartridge. pressure/check
sure of the pressure Open the shut ---off valve, the control
relief valve will soon valve in the venting valve and the inlet
be reached. line. valve.
Check the pressure
transducer.
Buffer battery Data---retention bat- Contact
tery run down. KAESER service.
bus alarm The bus link from Check link and plug. Check the interface
the Profibus DP in- configuration.
terface is interrup-
ted.
condensatedrain Fault in condensate Check condensate
drainage. drain and lines.
elect. equip. h The service interval Reset the service in- Check electrical
for checking electri- terval counter. components.
cal equipment and
wiring has expired.

9 --- 47
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
[Link] signal? External load signal Check settings of Check discrepan-
indistinct: the external control- cies between pres-
Increased cut ---out ler. sure transducers.
pressure exceeded. Take the pressure
The external load drops across filters
control has not and dryer into ac-
switched to idle. count.
error: RS 485 Wrong configuration Check the link/inter-
or transmission er- face connections
ror. between the two
Bit rate and charac- controllers.
ter frame for both Check maximum
subscribers identi- cable length and
cal. screening.
Check interface pa-
rameters.
1 master and 1 slave
configured.
ext. message 0 Rectify fault.
...
ext. message 5
flash memory Internal controller Exchange the cont-
memory error. roller.
mains voltage 1. power failure: Check power supply
Machine was re--- voltage.
started automati- Check door inter-
cally. lock.
modem problem SIGMA CONTROL Check the link be-
does not recognise tween the
the modem. SIGMA controller
and the modem.
motor T
Drive motor over- Ensure adequate
heating. ventilation.
Install an extractor.
Clean the motor.
motor bearings h  The service interval Change motor bear-
to the next motor ings.
bearing change has
expired.
motorstarts /h  The permissible Extend the idle pe- Check pressure
number of motor riod. transducer.
starts was exceeded Increase capacity of Replace defective
in the last 60 minu- air receiver. sensor.
tes.
Increase cross---sec-
tion of piping be-
tween compressor
and air receiver.

9 --- 48
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
motor starts /d The permissible Extend the idle pe- Check pressure
number of motor riod. transducer.
starts was exceeded Increase capacity of Replace defective
in the last 24 hours. air receiver. sensor.
Increase cross---sec-
tion of piping be-
tween compressor
and air receiver.
neutral p ---switch Rectify fault
neutral T---switch Rectify fault
no press. buildup The compressor Check for air leaks. Check the minimum
cannot build ---up Check the value gi- pressure/check
pressure. valve, the control
ven in the analog
data menu with the valve and the inlet
reading on the oil valve.
separator tank pres- Check venting valve.
sure gauge.
oil change h The service interval Change the cooling
to the next oil oil.
change has expired.
oil filter dp
Oil filter clogged. Change the oil filter.
oil filter h The service interval Change the oil filter.
to the next oil filter
check has expired.
oillevel  Oil level too low. Top up the cooling
oil.
oil T  Cooling oil tempera- Increase room tem- Replace defective
ture too low. perature. switch.
Check the oil circuit. Install auxiliary hea-
ting.
Check temperature
gauge switch, line
and connection.
PD temperature  Warning Check sensor, regu-
Compressor outlet lator.
temperature is low.
Check the frequency
converter.
PD temperature Warning Clean the cooler. Check the fan motor.
Compressor di- Check the cooling
scharge tempera- oil level.
ture too high.
RAM Internal RAM defec- Check controller.
tive. Exchange the cont-
roller.
Remaining oil con- Warning Check the scavenge Check the oil sepa-
tent
The purest class oil tube in the oil sepa- rator cartridge.
content limit will rator tank. Check oil sensor line
soon be reached. Check the dirt trap and connection.
strainer in the sca-
venge line.

9 --- 49
 Event Recognition and Fault Rectification

Message Possible cause Action KAESER service

technician only
Remaining oil The purest class oil Check the scavenge Check the oil sepa-
content content limit is ex- tube in the oil sepa- rator cartridge.
ceeded. rator tank. Check oil sensor line
Check the dirt trap and connection.
strainer in the sca-
venge line.
separator dp
Oil separator cart- Change the oil sepa-
ridge clogged. rator cartridge.
separator h The service interval Change the oil sepa-
to the next oil sepa- rator cartridge.
rator cartridge check
has expired.
set output The ’set output’ test End the ”set output”
function is activated. mode.
System pressure  System pressure Check air demand. Check pressure
has fallen below the Check line and con- transducer.
set ’low’ value. nection. Replace defective
Air consumption too Check ’systpress. sensor.
high. low’ setting.
System pressure
System pressure Check for air leaks.
(vacuum machines has fallen below the Check ’syspress.
only) set ’high’ value. high’ setting.
Check if the mac-
hine switches to
LOAD.
VFD mains Failure of power Check power
supply to the fre- supply.
quency converter.
V---belt tension V---belt tension too Re---tension the
low. V---belts.
V---belt tens. h The service interval Re---tension the
to the next V---belt V---belts.
re---tensioning has
expired.
Tab. 41 Warning messages and actions

9 --- 50
 Event Recognition and Fault Rectification

9.3 Miscellaneous faults

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

9 --- 51
 Event Recognition and Fault Rectification

Alarm Possible cause Action to take KAESER service

technician only
Cooling oil con- Unsuitable oil used. Use SIGMA FLUID
sumption too high. cooling oil.
Oil separator car- Change oil separ-
tridge split. ator cartridge.
Oil level in the sep- Drain off oil until the
arator tank too high. correct level is re-
ached.
Oil return line Check dirt trap in
clogged. the oil return line.
Tab. 42 Miscellaneous events (faults)

9 --- 52
 Maintenance

10 Maintenance

10.1 Safety
Disregarding these notes and/or improper handling may result in serious injury.

Electric shock can kill!

DANGER Touching electrically live components can cause serious injury or death.
Isolate completely from the mains supply (all conductors)
(switch off at the main isolator)
Ensure the supply cannot be switched on again (lock off).
Check that no voltage is present.
Only work on electrical components when they are voltage---free.
Work carefully.
Before switching on again ensure that:


no one is working on the machine,


all panels are in place and secured,


all access doors are closed.

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

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

Minimum pressure/check valves, pressure relief valves and inlet valves are
under powerful spring loading.
Do not open (dismantle) valves.

Compressed air can cause injury or death.

WARNING Serious injury or death can result from loosening or opening components
under pressure.
Close shut ---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the ma-
chine.
De---pressurize all pressurized components and enclosures.
Check all machine hose connectors with a hand ---held pressure gauge
to ensure that all read zero.

Machine damage from leakage

CAUTION Leaks result in loss of oil and reduced performance.

Damage or complete breakdown can result.
Test run after maintenance or service.
Carry out a visual check of the machine.

10 --- 53
 Maintenance

Maintenance work may only be carried out:

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

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

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

by persons trained in the machine under the supervision of an

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

10.2 Maintenance Schedule

Maintenance intervals are recommendations only and should be adjusted

to suit the installation and operating conditions.

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 10.16.

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 --- 54
 Maintenance

10.2.2 Regular maintenance work

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

when the equipment is heavily utilised, maintenance tasks must be carried
out more frequently (shorter intervals).

Heed controller maintenance messages.

Have KAESER service adjust the maintenance interval counters to
suit operating conditions.

Interval Maintenance tasks see chapter

Weekly Check cooling oil level. 10.11.1
Clean or renew the filter mats. 10.3.2 / 10.6
Every 1000 h Oil and air cooler maintenance. 10.3
Heat recovery system maintenance. 10.4
Clean the refrigerant condenser. 10.15.1
Indicated by Air filter maintenance. 10.5
SIGMA CONTROL
Indicated by Change the oil filter. 10.13
SIGMA CONTROL
but at least annu-
ally.
Indicated by Change the oil separator cartridge. 10.14
SIGMA CONTROL
but at least every
3 years.
Every 2000 h, but at Grease the motor bearings. 10.7
least annually.
Every 3000 h Check the coupling. 10.8
Variable (see Change the cooling oil. 10.12
Tab. 44)
Annually Check that all electrical connections are tight.
Check the pressure relief valve. 10.9
Check the oil and air coolers for leaks. 10.3
Cleaning the condensate drain 10.15.3
h = operating hours
Tab. 43 Regular maintenance work

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 44for future reference.

10 --- 55
 Maintenance

Cooling oil Maximum permissible oil change interval

[operating hours / year]
Favourable operat- Unfavourable oper- My operating condi-
ing conditions* ating conditions tions
SIGMA FLUID PLUS / 6 000* * / 2 3 000 / 1
S---460
SIGMA FLUID MOL 3 000 / 1 2 000 / 1
SIGMA FLUID FGL 3 000 / 1 2 000 / 1
SIGMA FLUID FGH 3 000 / 1 2 000 / 1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
* * Changing intervals > 6000 operating hours, permissible only with oil analysis.
Tab. 44 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
more frequently.

Interval Maintenance tasks

up to 12000 hours Check valves.
Up to 12000 hours, Change the fan motor bearings or the motor complete.
at the latest every
3 years
Up to 36000 hours, Change the drive motor bearings.
at the latest every Change the coupling.
8 years
Change the hose lines.
h = operating hours
Tab. 45 Regular service work intervals

10 --- 56
 Maintenance

10.3 Cooler Maintenance

10.3.1 Air cooling (option K1)

Material: brush
vacuum cleaner

Pre --- condition: Machine switched off.

Mains isolator locked off
Machine cooled down.

Check the cooler regularly for contamination. Frequency is mainly dependant on local op-
erating conditions.

Contamination causes overheating and machine damage.

Avoid dust disturbance. Wear breathing apparatus if necessary.

Do not use sharp objects to clean the cooler. The cooler could be damaged.
A severely contaminated cooler should be cleaned by a KAESER service agent.

Fig. 22 Cleaning the cooler

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

10.3.2 Filter mat maintenance (option K3)

Material: Warm water and household detergent

Spare parts (as required)

Pre --- condition: Machine switched off.

Mains isolator locked off
Machine cooled down.

10 --- 57
 Maintenance

Fig. 23 Cooler filter mats

1 Filter mat
2 Retaining frame
3 Fixing
Removal
Unlock the fixings (3).
Use a screwdriver to turn the fixing 90˚ anti---clockwise.
Remove the frame (2).
Cleaning
Beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary, wash the
mat in lukewarm water and household detergent then rinse thoroughly.
Renew the mat if cleaning is not possible of has already been carried out five times.
Replacing
Replace the frame and close the fixings.
Press and turn the fixings 90˚ clockwise until they latch.

10.3.3 Water cooling maintenance (option K2)

Pre --- condition: Machine switched off.
Mains isolator locked off
Machine cooled down.

Check the cooler regularly for leaks and contamination. Frequency of checking is depend-
ant on the characteristics of the cooling water.
Contamination causes overheating and machine damage.

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

Cleaning:
An authorised KAESER service agent should clean the cooler when the airend dis-
charge temperature is 10 ˚ C above the annual average.
Leakage
Pressure in the cooling oil circuit is generally higher than that in the cooling water system.
If a leak occurs, oil will run into the cooling water.
Check the cooler visually for leaks.
Have an authorised KAESER service agent check the cooler for internal leaks at least
once a year.

10 --- 58
 Maintenance

10.4 Internal Heat Recovery Maintenance (option W2 / W3)

Pre --- condition: Machine switched off.
Mains isolator locked off
Machine cooled down.

Deposits in the heat exchanger in machines with heat recovery systems can adversely af-
fect heat transfer.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is
dependant on the characteristics of the heat transfer medium.
Contamination
Have an authorised KAESER service agent clean the heat exchanger as soon as a
pressure drop in the heat transfer medium is detected.
Leakage
If a leak occurs, cooling oil can flow into the heat transfer medium as pressure the cooling
oil circuit is generally higher.
Check the heat exchanger visually for leaks.
Have an authorised KAESER service agent check the heat exchanger for internal leaks
at least once a year.

10.5 Air Filter Maintenance.

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

Pre --- condition: Machine is switched off

Mains disconnect is locked out
Machine is cooled down.

Fig. 24 Air filter maintenance.

1 Nut 3 Cover
2 Air filter cartridge 4 Nut

10 --- 59
 Maintenance

Open the air filter housing:

Unscrew the nuts (4) and lift out the cover (3) together with the air filter cartridge (2).
Unscrew the nut (1) and remove the air filter cartridge.

Do not clean the air filter cartridge with liquids.

All sealing surfaces are matched to each other.

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

Clean the air filter cartridge by tapping

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

Cleaning the air filter cartridge with compressed air:

Use dry compressed air (< 5 bar!) to blow dirt from the air filter cartridge at a slant
from the inside to the outside.

Close the air filter housing

Clean all parts and sealing surfaces.
Insert the air filter cartridge in the cover and affix with the nut (1).
Affix the cover in the machine with the nuts (4).
Close all access doors and replace all cover panels.
Switch on the power supply and reset the maintenance interval counter.

10.6 Filter mat maintenance (control cabinet)

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

Pre --- condition: Machine switched off

Mains disconnect is locked out
Machine is cooled down.

10 --- 60
 Maintenance

Fig. 25 Ventilator grill

1 Ventilator grill
2 Filter mat
Removal
Remove the ventilator grill (1) and the filter mat (2).
Cleaning
Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat
in lukewarm water (40 ˚ C) and household detergent then rinse thoroughly.
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.

10.7 Electric motor maintenance

Material: Bearing grease
Cleaning rags

Pre --- condition: Machine running.

Hot components --- danger of burning

CAUTION Wear long ---arm clothing and gloves.

Work carefully.
Compressor motor
The motor bearings are fitted with grease nipples.

High ---temperature grease ESSO UNIREX N3 should be used for re---greas-

ing the motor bearings. Bearing damages caused by the use of other
brands of grease are excluded from the warranty.

10 --- 61
 Maintenance

Fig. 26 Compressor motor maintenance

1 Grease nipple
Clean the grease nipple (1) with a rag.
Apply the quantity of grease as given on the motor nameplate.
Grease both bearings.
Close all access doors; replace and secure all removable panels.
Switch on the machine and reset the maintenance interval counter.

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

10.8 Checking the Coupling

Danger of injury from rotating coupling!

WARNING
Severe injury could result from touching the coupling while it is rotating.
Never switch the machine on without the guard in place over the
coupling.
The coupling must be carefully inspected at regular intervals.
A defective coupling is recognisable by:


noisy running,


surface cracks,


colour change.

Fig. 27 Checking the Coupling

1 Safety screen
2 Coupling

10 --- 62
 Maintenance

Check for uneven or noisy running

Switch the machine on.
Check the coupling (2) for noisy or uneven running.
Check for damage

Pre --- condition: Machine switched off.

Mains isolator locked off
Machine cooled down.

Remove the fixing screws from the safety screen (1).

Turn the coupling my hand and look for damage or colour change.
Have a damaged coupling changed by an authorised KAESER Service agent.
Refit the safety screen.
Close all access doors and replace all cover panels.

10.9 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.

There is danger of bursting if the permissible working pressure is ex-

ceeded.
WARNING
Noise from the pressure relief valve blowing off. Danger of scalding from
hot oil. Danger of injury from bursting components or the release of com-
pressed air.
Close all access doors; replace and secure all removable panels.
Wear ear and eye protection.
Work carefully.
Abort the test if the working pressure reaches 10% above the blowoff
pressure of the valve.

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

Blowoff protection and system 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.
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.
Replace a defective pressure relief valve.
Deactivate the test function.
Open the user’s shut ---off valve between the machine and the air main.

10 --- 63
 Maintenance

10.10 Venting the Machine Manually

Pre --- condition: Machine switched off.
Mains isolator locked off
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:


the oil circuit vents automatically when the machine is switched off,


air is vented manually from the oil separator tank,


air is vented manually from the air cooler.

Venting
Close the user’s shut ---off valve between the machine and the air main.

If no shut ---off valve is provided, the complete air system must be vented.

The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.

10 --- 64
 Maintenance

Fig. 28 Ventilate the machine.

1 Hose coupling (air cooler venting) 6 Male hose coupling/fitting
2 Pressure gauge 7 Shut ---off valve
A: closed
B: open
3 Hose coupling (oil separator tank ven- 8 Maintenance hose
ting)
Check that the oil separator tank pressure gauge reads zero.
After automatic venting the pressure gauge does not read zero?

Make sure that the shut ---off valve is closed.

If manual venting does not bring the oil separator tank pressure gauge
to zero, call KAESER service.
Manually venting the oil separator tank
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (3).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
Manually venting the compressed air cooler
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (1).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.

10.11 Checking and Topping up the Cooling Oil

10.11.1 Check cooling oil level.
Pre --- condition: Machine has been running at least five minutes under load.
(minimum 50 Hz for machines under frequency control).

Danger of burning from hot surfaces!

CAUTION Skin burns are possible.

Wear long ---arm garments and protective gloves.
Work carefully.

10 --- 65
 Maintenance

Fig. 29 Check cooling oil level.

2 Oil separator tank min Minimum oil level

3 Oil level indicator OK Oil level optimum
4 Indicator markings max Oil level maximum
5 Green zone
Readout oil level.
When the indicator shows minimum level, top up the oil.

10.11.2 Topping up the cooling oil

Material: Cooling oil

Pre --- condition: Machine switched off

Mains isolator locked off
Machine cooled down.

Danger of explosion from oils and lubricants!

WARNING
Danger of explosion from oil mist and vapours.
Fire, naked flame and smoking are forbidden!

Damage to the machine from unsuitable oil

CAUTION
Never mix different types of oil.

Top up only with the same type of oil as already in the machine.

Venting
Close the user’s shut ---off valve between the machine and the air main.

If no shut ---off valve is provided, the complete air system must be vented.

The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.

10 --- 66
 Maintenance

Fig. 30 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 ven- 7 Shut ---off valve
ting) 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 coupl-
ing (3).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
Manually venting the compressed air cooler
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl-
ing (1).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
Topping up the cooling oil
Open the filler plug (4) slowly.
Top up the cooling oil.
Replace the plug gasket if necessary and re---insert the plug.
Start the machine and carry out a test run
Close all access doors; replace and secure all removable panels.
Open the user’s shut ---off valve between the machine and the air main.
Start the machine and allow it to idle for at least one minute. Then switch to LOAD.
After about five minutes, check the oil level and top up if necessary.
Carry out a visual check for leaks.

10 --- 67
 Maintenance

10.12 Changing the cooling oil

Material: Cooling oil
Oil catchment container

Danger of burns from hot components and oil.

CAUTION
Wear long ---sleeved clothing and gloves.

Work carefully.

Dispose of the old oil in accordance with local environmental protection

regulations.

Drain the oil thoroughly from:

Oil separator tank


Oil cooler


The airend (if possible)


The heat recovery system (if installed).

Oil can only be drained from the airend when a hose coupling is provided.

Do not allow the compressed air to vent completely until the oil has
been drained from the airend.

Fig. 31 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)

10 --- 68
 Maintenance

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 is not operational
the machine is to be restarted after a long period of standstill.
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 mode 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 mains power supply switch.


Wait at least two minutes for oil to flow back to the separator tank.
Alternative: Changing the oil with help from an external pressure source

Pre --- condition: Machine switched off.

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

Close the shut ---off valve (10) in the venting line.


With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling
(3).


Connect the maintenance hose to an external air supply.


Open the shut ---off valve (7) until the pressure gauge on the oil separator tank reads
3 ---5 bar.


Close the shut ---off valve (7) and withdraw the hose fitting from the coupling.
Draining the oil from the separator tank:

Contact KAESER 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 coupl-
ing (9).


Place the end of the maintenance hose in the oil container and secure it in place.


Open the shut ---off valve (11).


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.

10 --- 69
 Maintenance

Draining the oil from the cooler

Fig. 32 Changing the cooling oil

1 Oil cooler 6 Male hose coupling/fitting

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

Have an oil container ready.

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

Airend hose coupling

yes no
Slowly open the shut off valve (7) in the Open the shut ---off valve (7) slowly and
maintenance hose and close immedi- allow oil and air to drain completely.
ately when air escapes.
Draining the oil from the airend. Check that the oil separator tank pres-
sure gauge reads zero.
Close the shut ---off valve (2) and unplug
the hose.

Drain the oil from the airend.

Oil can only be drained from the airend when a hose coupling is provided.

10 --- 70
 Maintenance

Fig. 33 Changing the cooling oil, airend

1 Airend discharge
2 Hose coupling (oil drain)
3 Shut ---off valve

Have an oil container ready.

With the shut ---off valve closed, insert the male hose fitting (6 in Fig. 32) 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).
Slowly open the shut ---off valve (7, Fig. 32) 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 oil filler plug (4, Fig. 31) slowly.
Fill with oil.

Machines with heat recovery systems need correspondingly more oil.

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

Start the machine and carry out a test run.

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

10 --- 71
 Maintenance

10.13 Oil filter maintenance

Material: Spare parts
Have the oil container ready.

Pre --- condition: Machine switched off

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

Danger of burning from hot components and oil.

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

Fig. 34 Changing the Oil Filter

1 Oil filter
2 Direction to unscrew

Dispose of parts and materials contaminated with oil in accordance with

local environment protection regulations.

Unscrew the oil filter anti---clockwise, catch oil spillage and dispose of correctly.
Lightly oil the new oil filter gasket.

Screw on the new filter using hand pressure only. Do not use any tool.

The oil filter is turned clockwise to tighten.

Start the machine and carry out a test run

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

10 --- 72
 Maintenance

After about five minutes, check the oil level and top up if necessary.
Carry out a visual check for leaks.

10.14 Changing the Oil Separator Cartridge

Material: Spare parts
Cleaning rags

Pre --- condition: Machine switched off.

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

The life of the oil separator cartridge is influenced by:

contamination in the air drawn into the compressor,


adherence to the schedule of oil and air filter changes,

Fig. 35 Changing the Oil Separator Cartridge

14 Cover 19 Pipe fitting

15 Dirt trap 20 Fitting
16 Air pipe 21 Gasket
17 Retaining screw 23 Oil separator cartridge
25 Minimum pressure/check valve

Unscrew the fitting (20) and carefully put the parts to one side; pull out the copper
pipe at item (15).
Unscrew the fittings (19) from the ends of the air pipe (16).
Withdraw the air pipe from the minimum pressure/check valve (25) and push carefully
to one side.
Remove the cover retaining screws (17) and carefully lift the cover (14).

10 --- 73
 Maintenance

The oil separator element cannot be cleaned.

Dispose of parts and materials contaminated with oil in accordance with

local environment protection regulations.

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

Start the machine and carry out a test run

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

10 --- 74
 Maintenance

10.15 Refrigeration Dryer

10.15.1 Cleaning the refrigerant condenser

Material: Compressed air

Vacuum cleaner

Pre --- condition: Machine switched off.

Mains power switch off and locked out.
Machine is cooled down.

Fig. 36 Refrigerant condenser

6 Screw compressors
7 Cover
8 Refrigerant condenser
Remove the screws (6) and take off the cover (7).
Use compressed air (< 5 bar) to blow the condenser (8) through from outside to in-
side and then vacuum up the dirt.
Replace the cover.

10.15.2 Testing condensate drainage

Pre --- condition: Machine running.

Hot components --- danger of burns

CAUTION
Wear long ---sleeved clothing.
Work carefully.
Condensate drains are found on the centrifugal separator and the refrigeration dryer.

10 --- 75
 Maintenance

Fig. 37 Testing the condensate drain

1 TEST button
Press and hold the TEST button (1) for at least two seconds.
The condensate drain opens.

Condensate does not drain out?

The drain line (hose) at the back of the drain is blocked.
Switch the machine off and clean or replace the drain hose.
Repeat the test.

Condensate does not drain out?

Condensate drain blocked.
Clean the condensate drain as described in chapter 10.15.3.

10.15.3 Cleaning the condensate drain

Material: Compressed air for blowing out

Cleaning rags
Spare parts (as required)

Pre --- condition: Machine switched off.

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

10 --- 76
 Maintenance

Fig. 38 Cleaning the condensate drain

1 Screw 7 Fitting
2 Diaphragm 8 Compression spring (valve core)
3 Screw 9 Valve core
4 Diaphragm seat 10 Casing
5 Compression spring (diaphragm) 11 Cap
6 Diaphragm cover
Removing the condensate drain
Close the shut ---off valve upstream of the condensate drain.
Unscrew the condensate drain hose fitting (7).
Unscrew the securing screws (1) and remove the drain.

Cleaning the condensate drain

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

Remounting the condensate drain

Secure the condensate drain with screws (1).
Re---connect the drain hose fitting and open the shut ---off valve upstream of the drain.
Close all access doors; replace and secure all removable panels.

10 --- 77
 Maintenance

10.16 Logging Maintenance Work

Machine number:
Date Maintenance task carried out Operating hours Signature

Tab. 46 Maintenance log

10 --- 78
 Spares, Operating Materiels, Service

11 Spares, Operating Materials, Service

11.1 Note the nameplate

Please quote the data on the nameplate for all enquiries and spare parts orders.

11.2 Ordering 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.
Machine

Name Quantity Number

Air filter cartridge 1 1250
Filter mat (control cabinet ventilator) 2 1100
Filter mat (cooler) 1 1050
Oil filter 1 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Bearing grease [g] 100 9.0915.0
400 6.3234.0
Tab. 47 Machine maintenance parts

11.3 Maintenance Contract

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

11.4 Service Addresses

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

11.5 Spare Parts for Service and Repair

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

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

11 --- 79
 De --- commissioning, Storage and Transport

12 De---commissioning, Storage and Transport

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

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

Run the machine once a week under load for at least 30 minutes to ensure corrosion
protection.
Out of service for a considerable period

Pre --- condition: When running for the last time before taking out of service the machine
should have run under load for at least 30 minutes.
Machine switched off and fully vented.
Main supply isolator switched off and locked.

Allow the machine to cool down completely.


In water ---cooled machines, disconnect the water supply and drain all water from the
machine.


Disconnect all air and electrical connections.

12.2 Packing
Material: Desiccant
Plastic sheeting
Wooden transport crate

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

Machine dry and cool.

Place desiccant inside the machine cabinet.


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

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

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


Prevent entry of moisture and condensation.

12 --- 87
 De --- commissioning, Storage and Transport

12.4 Transporting
Use only a fork truck or lifting cradle.
Take weight and centre of gravity into consideration. The centre of gravity is shown in the
drawing in chapter 13.2.3.

The water cooling system of water ---cooled machines must be drained

completely if there is danger of frost.

Fork truck

Pre --- condition: The whole machine is over the forks.

Fig. 39 Transport by fork truck

Lifting cradle

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

Fig. 40 Transport by lifting cradle

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

The sealed refrigerant circuit still contains both refrigerant and oil.
Both must be drained and disposed of by an authorised body.

12 --- 88
 De --- commissioning, Storage and Transport

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 --- 89
 Annex

13 Annex

13.1 Conformity
Machines with CE mark conform to European directives and may be operated in the EU.
A Declaration of Conformity is provided with the machine.

13.2 Diagrams and Drawings

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

13 --- 90
 Appendix

13.2.2 Pipeline and instrument flow diagram (option C1)

13 --- 96
 Appendix

13.2.3 Dimensional drawing

[Link] Air cooling (option K1)

13 --- 102
 Appendix

[Link] Water cooling (option K2)

13 --- 105
 Appendix

13.2.4 Electrical diagram

13 --- 108