Kaesser Screw Kompressor 8095A0SC338
Kaesser Screw Kompressor 8095A0SC338
Kaesser Screw Kompressor 8095A0SC338
Screw compressor
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 84
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 90
13.3 Dimensional drawing ........................................................................................................ 96
13.4 Electrical Diagram ............................................................................................................ 98
13.5 Service Manual for Compressed Air Filter ....................................................................... 115
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 supported.
DANGER
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruction.
➤ The measures required to protect yourself from danger are shown here.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
Option H1 ➤ This bullet is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used in
this service manual are explained in chapter 2.2 .
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protection.
2 Technical Data
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
Characteristic Value
Model
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQUIPMENT NUMBER
Tab. 2 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference.
Tab. 3 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equipment
fitted.
SX 3 SX 7.5
Weight [lb] 628 661
2.4 Temperature
SX 3 SX 7.5
Minimum cut-in tempera‐ 40 40
ture [°F]
Typical airend discharge 150–200 150–200
temperature during opera‐
tion [°F]
Maximum airend dis‐ 230 230
charge temperature (auto‐
matic safety shut-down)
[°F]
Tab. 5 Temperature
2.6 Ventilation
The values given are minimum guide values.
SX 3 SX 7.5
Inlet aperture Z see fig‐ 2.2 2.2
ure 14 [ft]
Exhaust fan for forced 883 1530
ventilation:
Flow rate [cfm] at 100 Pa.
Tab. 7 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
SX 3 SX 7.5
Safety relief valve activat‐ 230 230
ing pressure [psig]
SX 3 SX 7.5
Volume [gal] 70 70
SX 3 SX 7.5
Safety relief valve activat‐ 160 160
ing pressure [psig]
Measurement conditions:
■ Free-field measurement to CAGI/PNEUROP PN8 NTC 2.3
■ Measurement distance: 3.3 ft.
SX 3 SX 7.5
Sound pressure lev‐ 62 66
el [dB(A)]
M-SERIES:
■ M-Series SIGMA compressor cooling oils are semi-synthetic lubricants.
■ M-Series SIGMA compressor cooling oils are the highest quality petroleum lubricants. M–460 is
specially blended to provide reliable performance in KAESER screw compressors.
S-SERIES:
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
■ S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐
bricants. These ”synthetic” lubricants begin as high quality petroleum feed stock. They are then
refined, processed and purified into fluids with very consistent molecular structure. These oils are
carefully blended to produce extremely consistant lubricants with superior properties. SIGMA
synthetic lubricants feature all the advantages of both PAO and diester fluids.
■ S–460 lubricant is recommended for compressors operating in ambient temperatures between
40 °F and 105 °F.
SX 3 SX 7.5
Total charge [gall] 3.2 3.2
Topping up volume [quart] 0.13 0.13
(minimum–maximum)
The machine is designed for an electrical supply according to National Electric Code (NEC) NEC–
670, particulary NFPA 79, edition 2007, section 4.3. In the absence of any user-specified alternatives,
the limits given in these standards must be adhered to. Consult manufacturer for any other specific
power supply.
Three-phase
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on
power supplies like, for example, a three-phase (open) delta or three-phase star with non-grounded
neutral.
The machine requires a symmetrical three-phase power supply transformer with a WYE configuration
output as shown in Figure 2 and Figure 3. In a symmetrical three phase supply the phase angles and
voltages are all the same.
Other power supplies are not suitable.
Further information Please contact authorized KAESER Service representative for options.
The electrical diagram 13.4 contains further specifications for electrical connection.
SX 3 SX 7.5
Pre-fuse[A] 10 20
Supply 4xAWG14 4xAWG14
Consumption [A] 6.3 12
SX 3 SX 7.5
Pre-fuse[A] 10 15
Supply 4xAWG14 4xAWG14
Consumption [A] 5.7 10.7
SX 3 SX 7.5
Model *
*Transfer data from dryer nameplate to the table.
ABT 4 ABT 8
Pressure drop [psig] 1.6 1.6
(referred to 100 psig work‐
ing pressure)
Maximum permitted work‐ 232 232
ing pressure [psig]
Refrigerant circuit
The refrigeration dryer contains a refrigerant that is classified by the Kyoto Protocol as a fluoridised
global warming gas.
ABT 4 ABT 8
Refrigerant R 134a R 134a
Global warming potential 1300 1300
(GWP)
Charge quantity* [lb]
Maximum permitted work‐ 261 261
ing pressure [psig]
Safety pressure switch: 261 261
shutdown pressure [psig]
* Read off the charge quantity from the dryer nameplate and enter it in the table.
DANGER
Disregarding these instructions can result in serious injury.
➤ Read the service manual carefully and take notice of the contents for safe machine operation.
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for which
it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
➤ Ensure that operating, installation and maintenance personnel are qualified and authorized to
carry out their tasks.
3.5 Dangers
Basic Information
Information concerning the various forms of danger that can arise during machine operation are found
here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
Electricity
➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
qualified and authorized electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations .
➤ Before every start-up, the user must make sure there is adequate protection against electric shock
from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Switch off any external power sources.
These could be connections to floating contacts or electrical machine heating, for example.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in order.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or
death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
➤ Vent all pressurized components and chambers completely.
➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized components
(e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Spring tension
Springs under tension or compression represent contained energy. Uncontrolled release of this en‐
ergy can cause serious injury or death.
Minimum pressure/check valves, safety relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result in
serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before starting.
Temperature
Noise
Operating materials
➤ Use only spare parts approved by the manufacturer for use in this machine.
Unsuitable spare parts compromise the safety of the device.
➤ Use only genuine KAESER pressure components.
➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.
Transport
Installation
Further information More information on safety devices is contained in chapter 4, section 4.9.
3.8 In Emergency
3.8.1 Fire fighting
Suitable extinguishing media
■ Foam
■ Carbon dioxide
■ Sand or dirt
1. Keep calm.
2. Give the alarm.
3. Switch off the main power supply disconnect device if possible.
4. Move to safety:
■ warn any persons in danger
■ help incapacitated persons
■ close the doors
5. Try and extinguish the fire if you have the knowledge to do so.
Skin contact:
Inhalation:
➤ Remove the affected person to fresh air and make him or her rest.
➤ If breathing stops, apply artificial respiration and call for medical assistance.
3.9 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended under
the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user to
determine its suitability for his specific application.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
Fig. 5 Enclosure
1 Control cabinet door 5 Operating hours counter viewing window
2 Latch 6 Refrigeration dryer enclosure
3 Panel 7 Air receiver
4 Oil level indicator viewing window 8 Filter (optional)
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.
4.2 Function
The downstream refrigeration dryer removes moisture from the compressed air.
The condensate drain ejects the precipitate.
The compressed air stored in the air receiver filters out peaks in air consumption.
Condensate can be drained by a manually operated drain valve.
4.6 Options
The options available for your machine are described below.
4.6.1 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
➤ Contact KAESER with any queries concerning the use of the program module.
Connections
Delivery condition
■ The connections in the controller are wire bridged.
■ With the bridge in place, the compressor controller toggles the machine between LOAD and
IDLE.
■ The switching point is the system pressure setpoint.
➤ Reset to the delivery condition if the machine is to be regulated by the internal controller
and the program module is still plugged in.
Program module
At the end of the idling period, the compressor switches to STANDSTILL and is in stand-by. The
length of the idling period depends on the control mode being selected.
If the «ON» key is pressed while the remote contact is open, the machine remains in stand-by and
starts as soon as the remote contact closes.
➤ Set the setpoint pressure switching point 6 psig higher than the required compressed air
system pressure.
This ensures that in the event of the internal controller failing, the system pressure will regulate
according to the parameters of switching point and switching differential. This prevents exces‐
sively high system pressure by, say, a continuous external load signal.
4.6.3 Option F1
Microfilter
Fig. 10 Microfilter
1 Microfilter
2 Ball valve
The microfilter removes aerosols and solid particles from the compressed air.
Condensate is drained off by a ball valve.
4.6.4 Option F2
Activated carbon filter
The activated carbon filter removes oil and hydrocarbon vapours that can be adsorbed by activated
carbon, including solid particles, from the compressed air.
It is alwasy used together with a microfilter.
The SIGMA CONTROL BASIC can work with the following control modes:
■ DUAL
■ QUADRO
Option C1 ■ MODULATING control
The SIGMA CONTROL BASIC is factory set to QUADRO control mode unless specifically ordered
otherwise.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain pressure between the preset minimum and maximum values. When maximum pressure is
reached, the machine switches to IDLE. When the preset idle period has elapsed, the machine
switches to STANDSTILL.
The idling time is fixed in SIGMA CONTROL BASIC.
QUADRO
In the QUADRO mode, the controller operates as in the DUAL mode during periods of high air demand
by switching between LOAD and IDLE, but during periods of low air demand it switches directly to
STANDSTILL.
This mode of control requires two preset time periods: the running period and the idle/standstill pe‐
riod.
The idling/stopped and the running time are set in SIGMA CONTROL BASIC.
MODULATING control is based on the DUAL control mode. The difference to DUAL is that the gas
delivery is continuously varied within the control range of the machine.
This control mode is not available on variable speed machines with a frequency-controlled
drive (SFC).
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.
Fig. 12 Keys
Tab. 24 Keys
Fig. 13 Indicators
Tab. 25 Indicators
Tab. 26 Display
4.11.2 Parameters
Parameters Meaning
0 Operating hours counter
Displays the period during which the drive motor was switched on.
KAESER Service reserve the right to change these parameters.
1 Load hours counter
Shows the number of hours the drive motor has run under LOAD.
KAESER Service reserve the right to change these parameters.
2 Maintenance interval counter
Displays the number of operating hours until the next scheduled maintenance is due.
SIGMA CONTROL BASIC counts down the operating hours from a default value. The
warning message 'S' is displayed when the counter reaches zero.
The maintenance interval counter is reset to its default value after the maintenance
work has been carried out. The interval starts anew.
A password is required to change these parameters.
3 Relief valve test mode
This function switches the activating pressure check mode for the pressure relief valve
on and off.
The warning message i is displayed when the check mode is switched on.
See chapter 10.9 for the password and carrying out the check.
A password is required to change these parameters.
4 Unit of measurement for display of temperature
The airend discharge temperature can be displayed in either °C or °F.
5 Unit of measurement for display of pressure
The current working pressure can be displayed in bar, psi or MPa.
6 Control modes
Factory setting: OFF
Parameters Meaning
8 Switching the refrigeration dryer on and off
Factory setting: ON
Tab. 27 Parameters
Further information Means of changing or adjusting parameters are given in chapter 8.4.
4.11.3 Messages
Alarm message
An alarm shuts the machine down automatically. The red LED 13 flashes (figure 13).
Warning message
Precondition The floor must be level, firm and capable of bearing the weight of the machine.
CAUTION
Ambient temperature too low.
Frozen condensate and highly viscous cooling oil can cause damage when starting the machine.
➤ Make sure that the temperature of the machine is at least +37 °F before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
1. If installed outdoors, protect the machine against frost, direct sunlight, dust and rain.
2. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
➤ Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually
open.
➤ Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
Further information Further information on installation of exhaust air ducts can be found in chapter 13.3.
6 Installation
6.1 Safety
The following instructions must be followed for safe installation.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
WARNING
Serious injury or death can result from loosening or opening components under pressure.
➤ Vent all pressurized components and chambers completely.
DANGER
Danger of fatal injury from electric shock!
➤ Switch off and lock out the supply disconnecting device and check that no voltage is present.
Further information The electrical diagram 13.4 contains further specifications for electrical connection.
6.4.1 Option T2
Refrigeration dryer: Connecting the transformer according to the power supply.
The refrigeration dryer transformer has tappings for various power supply voltages.
1. Check that the correct connections are made for the supply voltage provided for the machine.
2. If necessary, re-connect the transformer to match the power supply voltage.
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.
Further information The dimensional drawing in chapter 13.3 gives the size and position of the condensate drainage
connection ports.
6.6 Options
6.6.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3.
1. Lay the cable so that it does not come under tension when the control cabinet door is opened.
2. Strip 0.5 in. of insulation from the ends of the conductors.
3. Use a screwdriver to open the spring-loaded terminals and insert the ends of the conductors in
the square openings above the corresponding terminals.
4. Secure the cable so there is no tension on the X2 plug.
5. Seal the cable lead through against ingress of dirt or moisture.
7 Initial Start-up
7.1 Safety
The following instructions must be followed for safe machine commissioning.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
➤ Commissioning of the machine may only be carried out by trained and authorized installation or
maintenance personnel.
In direct online starting, the motor supply current is fed via the overload protection cut-out (see name‐
plate on the control cabinet for motor nominal current).
To prevent the overload protection cut-out from being triggered by voltage fluctuations, tem‐
perature influences or component tolerances, the setting can be higher than the rated motor
current.
➤ Check the overload protection cut-out setting.
The overload protection cut-out shuts the machine down despite being correctly set?
➤ Contact KAESER Service.
Wye-delta starting
In wye-delta start the phase current is fed via the overload protection cut-out. This phase current is
0.58 times the rated motor current (see nameplate in the control cabinet).
To prevent voltage fluctuations, temperature influences or component tolerances operating the
overload protection cut-out, the setting can be higher than the arithmetical phase current.
CAUTION
Higher altitude.Frozen condensate can damage the dryer.
➤ An adjustment must be made to the hot gas bypass valve if the dryer is used at altitudes above
3000ft.
1. Set the hot gas bypass valve according to the following illustrations and table.
3280 0
3937 23
4593 47
5249 70
5905 93
6562 116
7218 140
7874 163
8530 186
9186 210
9843 233
10498 256
11155 279
11811 303
12467 326
13123 349
2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
3. Turn the rotors manually by means of the belt pulley to distribute the oil.
Machines of this type are generally only lightly utilized. Condensate can build up in lightly utilized
machines with detrimental effects to the cooling oil and the machine itself. You can determine if your
machine falls into this category by regular sampling of the cooling oil during the first week of operation.
➤ Make sure you are familiar with the procedure before draining off any oil.
➤ A small quantity of cooling oil should be drained out to check for condensate at least once a week
during the first 4 weeks of operation.
Further information Information on draining off cooling oil is given in chapter 10.14.
1. Scroll with the arrow keys until the parameter D "setpoint pressure: switch.point" is displayed in
line 3.
2. Press and hold «enter» for at least 3 seconds until the cursor flashes.
3. Use the arrow keys to set the desired switching point and confirm with «enter».
This switching differential is factory set. Adjust this parameter if the motor starting frequency is too
high.
1. Scroll with the arrow keys until the parameter C "setpoint pressure: switching differential" is dis‐
played in line 3.
2. Press and hold «enter» for at least 3 seconds until the cursor flashes.
3. Use the arrow keys to set the desired differential and confirm with «enter».
8 Operation
8.1 Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.
8.1.1 Switching on
Precondition No personnel are working on the machine
All access doors and panels are closed and secure.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
out pressure).
LOAD IDLE
The machine switches to IDLE. The motor stops immediately.
The Machine ON LED flashes. The Machine ON LED extinguishes.
The drive motor comes to a stop after
about 15 seconds.
The Machine ON LED extinguishes.
Shutdown
Switching on
1. Turn the EMERGENCY STOP pushbutton in the direction of the arrow to unlatch it.
2. Press the reset key to reset any alarm messages.
The machine can now be started again.
Alarm message
or
➤ Rectify the fault and acknowledge the message with the «acknowledge» key.
alarm LED extinguishes.
The machine is now ready to start again.
Warning message
If no key is pressed for ten seconds in the edit mode, the display automatically returns to the
previous mode.
Restarting the controller is not necessary. Edited parameters are immediately effective.
Network pressure and airend discharge temperature are neither updated nor displayed while
in the edit mode.
1. Scroll with the «UP»/«DOWN» keys until the desired parameter appears in line 3.
2. Depress the «enter» key for at least 3 seconds.
Result Depending on the parameter, either the displayed value or the first character of the required password
flashes.
➤ Use the «UP»/«DOWN» keys to change the value of the parameter and confirm with «enter».
Some parameters can only be edited after a password has been entered.
Password: BASIC
This password will be automatically reset if no key is pressed within 5 minutes.
1. Select the first character with the «UP»/«DOWN» key and confirm with «enter».
The next character flashes.
2. Repeat until all characters have been entered.
When the correct password is entered the parameters are displayed.
3. Use the «UP»/«DOWN» keys to change the value of the parameter and confirm with «enter».
The messages valid for your machine are dependant on the controller and individual equipment.
1. Do not attempt fault removal measures other than those given in this manual.
2. In all other cases:
have the fault rectified by an authorized KAESER Service representative agent.
10 Maintenance
10.1 Safety
The following instructions must be followed for safe machine maintenance.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut-off valves or otherwise isolate the machine from the air main to ensure that no com‐
pressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
➤ Please observe national regulations regarding the use of cooling oil in oil-injected screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary.
KAESER LUBRICANTS
SIGMA Lubricant Description Maximum Recommended Change Interval
First oil change Subsequent oil change
M–460 ISO 46 Semi-Synthetic 2,000 Hours 3,000 Hours
Lubricant
S–460 ISO 46 Synthetic Lubri‐ 6,000 Hours 8,000 Hours
cant
S–680 ISO 68 Synthetic Lubri‐ 6,000 Hours 8,000 Hours
cant
FG–460 ISO 46 Food Grade 2,000 Hours 3,000 Hours
Synthetic Fluid
1. Carefully remove the ventilation grill 1 and take out the filter mat 2 .
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Change the filter mat if cleaning is not possible or if the change interval has expired.
4. Lay the filter mat in the frame and latch in the ventilation grill.
A filter mat helps to keep the cooler clean but cooler cleaning is necessary after a period of time.
Do not clean the cooler with a sharp instrument, otherwise it could be damaged.
Avoid dust disturbance.
1. Carefully remove the filter mat from the retaining frame.
2. Dry brush the oil and air coolers and use a vacuum cleaner to remove the dirt.
3. Carefully insert the filter mat in the retaining frame.
The air and oil coolers can no longer be properly cleaned?
➤ Heavy and stubborn contamination should be removed by authorized KAESER Service
representative.
WARNING
Touching moving drive belt may result in severe bruising or even loss of limb or extremities.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
1. Turn the pulley by hand so that all of the belt can be inspected for damage.
2. Change the belts immediately if any damage is found.
The drive motor must be moved in its bracket to change the belts. Use the appropriate tool and support
the motor during belt changing.
➤ Relief valves on machines with maximum permissible working pressure of 217 psig should
be tested only by KAESER Service.
Blow off protection and air system pressure monitoring are switched off during the test.
The machine must be isolated from the compressed air network and completely vented before
undertaking any work on the pressure system.
➤ Never operate the machine without correctly functioning pressure relief valves.
1. Close the user's shut-off valve between the machine and the air distribution network.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Scroll to parameter 3 "Pressure relief valve check mode" with the arrow keys and confirm by
depressing the «enter» key for at least three seconds.
4. Enter the password "BASIC" and confirm with the «enter» key.
5. Use the arrow keys to select parameter "on" and confirm.
WARNING
The pressure relief valve may blow off at any time!
Excessive noise is caused when the pressure relief valve blows off!
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air!
➤ Close all access doors and replace and secure all removable panels.
➤ Wear ear and eye protection.
➤ Abort the test if the working pressure rises 10% above the activating pressure of the valve.
1. Call up the edit mode again and enter the password "BASIC".
2. Use the arrow keys to set the parameter to "off" and confirm with the enter key.
3. Open the user's shut-off valve between the machine and the air distribution network.
The ideal situation is with the oil level around the optimum mark when the machine is running.
Operating state Minimum oil level Maximum oil level
LOAD
Precondition The machine has been running at least 5 minutes under LOAD.
Material The hose coupling, shut-off valve and maintenance hose lie beneath the oil separator tank.
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.
➤ Close the user's shut-off valve between the machine and the compressed air system.
If no shut-off valve is provided, the complete compressed air system must be vented.
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at a person while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 psig.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the compressed air system is vented to
atmospheric.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Withdraw the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an
authorized KAESER Service representative.
After shutting down the compressor and venting the oil separator tank, there is still pressure on
the machine from the compressed air system or in the section from the shut-off valve to the
minimum pressure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Withdraw the male hose fitting 6 and close the shut-off valve 7 .
Material The hose coupling, shut-off valve and maintenance hose lie beneath the oil separator tank.
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.
➤ Close the user's shut-off valve between the machine and the compressed air system.
If no shut-off valve is provided, the complete compressed air system must be vented.
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at a person while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 psig.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the compressed air system is vented to
atmosphere.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Withdraw the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an
authorized KAESER Service representative.
After shutting down the compressor and venting the oil separator tank, there is still pressure on
the machine from the compressed air system or in the section from the shut-off valve to the
minimum pressure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Withdraw the male hose fitting 6 and close the shut-off valve 7 .
A sticker on the oil separator tank gives the type of oil it contains.
CAUTION
The machine could be damaged by unsuitable oil
➤ Never mix different types of oil.
➤ Top up only with the same type of oil as already in the machine.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air system.
3. After about 10 minutes, check the oil level again and top up if necessary.
4. Switch off the machine and visually check for leaks.
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
Changing the oil with internal pressure Changing the oil using an external compressed
air source
The machine has been running for at least 5 mi‐ The supply disconnecting device is switched off,
nutes under LOAD. the device is locked off,
The machine is fully vented, the pressure gauge a check has been made that no voltage is present.
on the oil separator tank reads 0 psig. The machine is fully vented, the pressure gauge
1. Close the shut-off valve 10 in the venting on the oil separator tank reads 0 psig.
line. An external source of compressed air is available.
2. Start the machine and watch the oil separator 1. Close the shut-off valve 10 in the venting
tank pressure gauge 2 until it reads 43–72 line.
psig. 2. With the shut-off valve closed, insert the male
3. Switch off and lock out the power supply dis‐ hose fitting 6 into the hose coupling 3 .
connecting device and check that no voltage 3. Connect the maintenance hose to the exter‐
is present. nal air supply.
4. Wait at least 2 minutes to allow the oil to flow 4. Open the shut-off valve 7 until the pressure
back to the separator tank. gauge on the oil separator tank reads 43–72
psig.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
5. Switch off the machine and check visually for leaks.
All the cooling oil has run out of the filter 1–2 minutes after shutting down. A cooling oil receptacle is
not needed.
Material Spares
Cleaning cloths
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
1. Unscrew the oil filter counter-clockwise and wipe off any drops of oil.
2. Lightly oil the new filter's gasket.
3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. After about 10 minutes, check the oil level again and top up if necessary.
5. Switch off the machine and check visually for leaks.
All the cooling oil has run out of the separator cartridge 1–2 minutes after shutting down. A cooling
oil receptacle is not needed.
Material Spares
Cleaning cloths
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
1. Unscrew the oil separator cartridge counter-clockwise and wipe off any drops of oil.
2. Lightly oil the new filter's gasket.
3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Stop the machine after 10 minutes and visually check for leaks.
➤ Check and clean the refrigerant condenser and condensate drain regularly as described below.
Precondition The machine has run for a sufficient period under LOAD.
The Power LED lights.
Thee Alarm LED (if provided) does not light.
➤ Visual check: Does condensate flow as soon as the drain automatically opens?
Condensate does not flow?
The condensate drain hose or the drain itself is blocked.
➤ Switch off the machine and clean the drain pipe.
➤ Condensate drain manual check: Press and hold the «TEST» button for at least 2 seconds.
➤ Carry out maintenance on the condensate drain if condensate still does not flow.
➤ Collect condensate in a suitable container and dispose of in accordance with environmental
regulations.
Use only KAESER Service modules to ensure correct function of the condensate drain.
Precondition Make sure the top of the service module and the contact spring are clean and dry.
1. Screw the service module to the inlet pipe using sealing tape.
2. Insert the control module sensor 3 carefully in the opening 4 in the new service module.
3. Place the hook of the control module into the service module eye and press until the snap fastener
can be heard to click into place.
4. Fit the drain hose and open the shut-off valve upstream of the condensate drain.
5. Close all access doors, replace and secure all removable panels.
1. Undo the knurled screw on the condensate drain tap and drain the condensate into a suitable
canister.
2. Close the condensate drain tap.
➤ Dispose of the condensate according to valid environmental regulations.
1. Close the user's shut-off valve between the machine and the compressed air system.
2. Switch the machine on until the air receiver is full.
(machine switches to IDLE running)
3. Shut down the machine and remove the panel on the air receiver.
4. Turn the ring 1 until the safety relief valve opens.
5. Turn the ring 1 back again.
6. Open the user's shut-off valve between the machine and the compressed air system.
The safety relief valve does not open?
➤ De-commissioning the machine until the defective safety relief valve is replaced.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuitable con‐
sumable parts or operating fluids/materials.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from machine damage.
➤ Use only genuine KAESER parts and operating fluids/materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.
Machine
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protection
against corrosion.
Precondition Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the power supply disconnecting device,
the disconnect device is locked in the off position,
check that no voltage is present.
Machine fully vented (no pressure).
12.2 Packing
A wooden crate is required for ground transport to protect the machine from mechanical damage.
Consult an authorized KAESER Service representative for advice on packing for sea or air transport.
Material Desiccant
Plastic sheeting
Wooden transport crate
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and oil separator tank.
Frozen moisture can damage components, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and re-commissioning.
CAUTION
Machine damage from moisture and frost.
➤ Prevent ingress of moisture and condensation.
➤ Maintain >32 °F storage temperature.
12.4 Transporting
12.4.1 Safety
Weight and center of gravity determine the suitable transporting method. The center of gravity is
shown in the drawing in chapter 13.3.
Precondition Transport only by fork truck or lifting cradle and with personnel trained in the safe use of the transport
equipment.
➤ Drive the forks completely under the machine or palette and lift carefully.
CAUTION
Machine damage by incorrect lifting cradle attachment.
➤ Do not attach the lifting cradle to any of the machine components.
➤ The machine manufacturer can advise on application of a suitable lifting cradle.
➤ Use the lifting cradle correctly and lift the machine carefully.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove dirty filters.
The sealed refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by authorized personnel.
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13.2 Option C1
Pipe and Instrument Flow Diagram (P+I diagram): MODULATING
control mode