Kaeser Dsd100-175 Sigma Control2
Kaeser Dsd100-175 Sigma Control2
Kaeser Dsd100-175 Sigma Control2
Screw Compressor
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of disregard
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
Example:
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.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
Option H1 ➤ This symbol denotes lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with screw-in machine feet). Option codes 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 ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
Characteristic Value
Screw Compressor
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQUIPMENT NUMBER
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference.
Tab. 4 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equip‐
ment fitted.
2.4 Temperature
DSD 100 DSD 125 DSD 150 DSD 175
Minimum cut-in tempera‐ 40 40 40 40
ture [°F]
Typical airend discharge 150–200 150–200 150–200 150–200
temperature during oper‐
ation [°F]
Maximum airend dis‐ 230 230 230 230
charge temperature (au‐
tomatic shut-down) [°F]
Tab. 6 Temperature
2.6 Ventilation
Values given are minimum guidelines.
Tab. 8 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
Maximum working pres‐ DSD 100 DSD 125 DSD 150 DSD 175
sure [psig]
110 — — — 145
125 — — 145 —
130 170 170 — —
175 205 205 205 205
217 — — — 232
2.8 Delivery
FAD [cfm]
Maximum working pres‐ DSD 100 DSD 125 DSD 150 DSD 175
sure [psig]
110 439 573 674 851
125 436 570 671 660
130 434 569 — —
175 367 424 544 636
217 — — — 526
Tab. 10 Delivery
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.
Option K2 Water-cooled
Option W1 The charge of cooling oil for machines with heat recovery is increased by the volume of oil in the
heat exchanger and connecting lines:
DSD 100 DSD 125 DSD 150 DSD 175
Additional charge vol‐
ume [quart]*
* Enter the volume required by your heat recovery system.
Maximum working pres‐ DSD 100 DSD 125 DSD 150 DSD 175
sure [psig]
110 1792 1792 1792 1794
125 1792 1792 1792 1794
130 1188 1792 — —
175 1188 1188 1792 1794
217 — — — 1794
2.11.2 Option K1
Fan motor
Rated power supply: 380V±10%/3/60Hz
2.11.3 Option K2
Fan motor
Rated power supply: 380V±10%/3/60Hz and 460V±10%/3/60Hz
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 alterna‐
tives, 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 configura‐
tion output as shown in Figure 2 and Figure 3. In a symmetrical three phase supply the phase an‐
gles 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.
DSD 100 DSD 125 DSD 125 DSD 150 DSD 175
130 psig 175 psig
Mains fusing [A] 225 250 250 300 400
Supply cable 4 x AWG 4/0 2x4 x AWG 2x4 x AWG 2x4 x AWG 2x4 x AWG
1/0 1/0 2/0 3/0
Current drawn [A] 155/152* 190/186* 175/172* 227/222* 274/269*
* Option K2
460V±10%/3/60Hz
DSD 100 DSD 125 DSD 125 DSD 150 DSD 175
130 psig 175 psig
Mains fusing [A] 175 225 225 250 300
Supply cablel 4 x AWG 3/0 4 x AWG 4/0 4 x AWG 4/0 2x4 x AWG 2x4 x AWG
1/0 2/0
2x4 x AWG
1*
Current drawn [A] 132/129* 158/156* 150/147* 186/182* 225/220*
* Option K2
575V±10%/3/60Hz
DSD 100 DSD 125 DSD 125 DSD 150 DSD 175
130 psig 175 psig
Mains fusing [A] 150 175 175 225/200* 250
Supply cable 4 x AWG 1/0 4 x AWG 3/0 4 x AWG 3/0 4 x AWG 4/0 4 x MCM
250
Current drawn [A] 103/101* 128/126* —/—* 152/149* 178/175*
* Option K2
2.15 Option K2
Water-cooling
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connec‐
tion ports.
Cooler specification
Characteristics/content Value
pH value 7.5–9
Hardness [dH] 4.0–8.5
Chloride (Cl) [mg/l] <150
Free chlorine gas (Cl2) [mg/l] <1
Sulphite (SO3) [mg/l] <1
Dissolved iron (Fe) [mg/l] <0.2
Hydrogen carbonat (HCO3) [mg/l] 70–300
Sulphate (SO4) [mg/l] <70
HCO3/SO4 >1
Electrical conductivity [µS/cm] 10–500
Ammonia (NH3) [mg/l] <2
Dissolved manganese (Mn) [mg/l] <0,1
Dissolved aluminium (Al) [mg/l] <0,2
Dissolved nitrate (NO3) [mg/l] <100
Hydrogen sulphide (H2S) [mg/l] <0,05
Free aggressive carbon dioxide (CO2) [mg/l] <5
Glycol [%] <50
Solids (particle size) [mm] <0,1
Algae Not permitted
Maximum heat capacity DSD 100 DSD 125 DSD 150 DSD 175
available*
[kW] 65.7 76.1 96.8 118.6
[MJ/h] 236 274 348 427
[kcal/h] 56475 65417 83233 101943
* With the combination valve set to open at 176 °F.
Characteristics/content Value
pH value 7,5–9
Hardness [°dH] 4,0–8,5
Chloride (Cl) [mg/l] <150
Free chlorine gas (Cl2) [mg/l] <1
Sulphite (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 [µS/cm] 10–500
Ammonia (NH3) [mg/l] <2
Dissolved manganese (Mn) [mg/l] <0,1
Dissolved aluminium (Al) [mg/l] <0,2
Dissolved nitrate (NO3) [mg/l] <100
Hydrogen sulphide (H2S) [mg/l] <0,05
Free aggressive carbon dioxide (CO2) [mg/l] <5
Glycol [%] <50
Solids (particle size) [mm] <0,1
Algae not permitted
heating power
Maximum heat capacity DSD 100 DSD 125 DSD 150 DSD 175
available*
[kW] 65.7 76.1 96.8 118.6
[MJ/h] 236 274 348 427
[kcal/h] 56475 65417 83233 101943
* With the combination valve set to open at 176 °F.
Option W2 Flow rate for heating from 113 °F to 158 °F (equivalent to ΔT = 45°F)
➤ 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 instructions
The following describes the various forms of danger that can occur during machine operation.
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
Touching voltage carrying components can result in electric shocks, burns or death.
➤ 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 commissioning or re-commissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply isolator and verify the absence of any voltage.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or the electrical machine heating, for ex‐
ample.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.
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 distribution network to ensure
that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Do not carry out welding, heat treatment or mechanical modifications on pressurized compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
The composition of the compressed air must be suitable for the actual application in order to pre‐
clude health and life-threatening dangers.
➤ Use appropriate systems for air treatment before using the compressed air from this machine
as breathing air and/or for the processing of food products.
➤ Use food-grade cooling oil whenever compressed air is to come into contact with food prod‐
ucts.
Spring forces
Springs under tension or compression store energy. Uncontrolled release of this energy 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.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air lines, cool‐
ers, oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
The blowing-off of the safety relief valve can be particularly loud.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapor.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
If dimensioned appropriately, safety relief valves reliably prevent an impermissible rise in pressure.
New dangers may arise if you modify or extend the compressed air station.
➤ When extending or modifying the compressed air system:
Check the blow-off capacity of safety relief valves on air receivers and compressed air lines
before installing a new machine.
➤ If the blow-off capacity is insufficient:
Install safety relief valves with larger blow-off capacity.
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Transporting
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the center of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Assembly
➤ Only use only electrical cables that are suitable and approved for the surroundings and electri‐
cal loads applied.
➤ Never dismantle compressed air pipes until they are fully vented.
➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Positioning
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements regarding explosion protection are in
force.
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance: explosive or chemically instable gases and vapors,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in warm cooling outlet air from other machines.
➤ Keep suitable fire extinguishing agents ready for use.
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorized personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ De-pressurize all pressurized components and enclosures.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Do not open or dismantle any valves.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Carry out regular inspections:
for visible damages,
of safety installations,
of the EMERGENCY STOP command device,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
Further information More information on safety devices is contained in chapter 4, section 4.5.
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
➤ Shut off supply lines if possible.
Mains disconnecting device (all poles)
Cooling water (if present)
Heat recovery (if present)
➤ Warn and move endangered personnel to safety.
➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
Skin contact:
Inhalation:
Ingestion
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 un‐
der 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.
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.
4.3 Options
The options available for your machine are described below.
4.3.1 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
4.3.2 Option K2
Water-cooling
Plate heat exchangers in stainless steel are used for water-cooled machines.
4.3.3 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
The cooling oil is kept at the ideal temperature for machine operation.
The thermostatic valve opens first so that heat is given up to the heat recovery system. If the heat
recovery system cannot carry away enough heat, the combination valve opens to allow hot oil
through the oil cooler circuit.
Operation:
combination valve opening temperature = thermostatic valve opening temperature
The available heat to be recovered depends on the operating conditions of the machine.
Both oil temperature regulators are equipped with working elements that ensure trouble-free func‐
tioning of the cooling and heat recovery systems.
The SIGMA CONTROL 2 controller is factory set to DYNAMIC 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 the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed the machine is STOPPED.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor. The shorter the idling time setting, the sooner (and more frequently) the motor is stopped.
QUADRO
Unlike DUAL regulating mode, the machine will switch from LOAD to STANDSTILL in QUADRO
mode after periods with low compressed air consumption.
After periods with a high compressed air consumption, the machine will switch from LOAD to
STANDSTILL after passing through IDLE.
In this control mode, the controller requires two specified times: The running time and the idling/
standstill time.
The shorter these times are set, the sooner (and more frequently) the motor is stopped.
VARIO
The VARIO mode is based on the DUAL regulating mode. Unlike DUAL control mode, the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
DYNAMIC
The DYNAMIC mode is based on the DUAL control mode. Unlike DUAL regulating mode, this con‐
trol mode switches the drive motor directly to STANDSTILL at low temperature. At higher motor
temperatures, it switches to IDLE until the motor has cooled down enough.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is
stopped.
MODULATING control is based on the DUAL control mode. Unlike DUAL regulating mode, the air
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).
Tab. 41 Keys
Indicators
Fig. 12 Indicators
Tab. 42 Indicators
RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID sensor field of the controller will automatically
activate the communication between transponder and SIGMA CONTROL 2 .
A suitable transponder is the EQUIPMENT CARD. Two of them have been provided with the ma‐
chine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.
➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of
the machine room.
1. 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.
2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac‐
tually open.
3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
4. Ensure clean air in order to support the proper functioning of the machine.
Further information Further information on the design of exhaust air ducts can be found in chapter 13.3.
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 psig.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Do not open the cabinet while the machine is switched on.
➤ Do not induce any forces into the machine for which the compressive forces must be bal‐
anced by bracing.
1. Serious injury or death can result from loosening or opening components under
pressure.
➤ Depressurize all components and enclosures that are subjected to pressure.
2. A shut-off valve must be installed by the user in the connection line.
3. Connect the axial compensator or flexible hose.
Further information The dimensional drawing in chapter 13.3 provides the size and position of the connection ports.
1. The power supply must only be connected by authorized installation personnel or an author‐
ized electrician.
2. Carry out safety measures as stipulated in relevant regulations. In addition, observe the regula‐
tions of the local electricity supplier.
3. Test the overcurrent protection cut-out to ensure that the time it takes to disconnect in re‐
sponse to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the sup‐
ply voltage.
If not, change the tappings to suit the power supply voltage.
7. Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
voltage.
8. Connect the machine to the power supply.
9. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.
6.5 Options
6.5.1 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.
6.5.2 Option K2
Connecting the cooling water
➤ Take the electrochemical series into consideration and choose suitable materials for wa‐
ter connections.
➤ Keep the effect of pressure surges on the coolers as low as possible.
➤ Install an expansion tank to act as a pulsation damper if pressure surges cannot be
avoided.
➤ Avoid a low inlet temperature for the cooling water as it can cause condensation. If re‐
quired, contact KAESER for suitable insulation measures.
Temperature-controlled cooling water supply systems, to which numerous machines are connect‐
ed, regulate the water flow rate according to the difference in temperature between the supply and
the return water. Individual machines may not receive an adequate flow under this system. Break‐
downs are the result.
➤ KAESER can advise on how to ensure the cooling water supply via suitable control
valves.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connec‐
tion ports.
➤ Install the heat recovery system in accordance with the following specifications.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connec‐
tion ports.
6.5.3.1 Option W1
Connecting the external heat recovery system
An unsuitable heat exchanger or incorrect installation may adversely impact the cooling oil
circuit within the compressor. Damage to the machine will follow.
➤ Consult with KAESER on a suitable heat exchanger and have an authorized KAESER service
representative do the installation.
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.
Warning instructions are located before a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ De-pressurize all pressurized components and enclosures.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 psig.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Do not open the cabinet while the machine is switched on.
Fig. 19 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
88 psig 176 ° F
–––––––– Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
▶2 xxxxxxxxxx Submenu
▶3 xxxxxxxxxx Submenu
▶4 xxxxxxxxxx Submenu
▶5 xxxxxxxxxx Submenu
▶6 xxxxxxxxxx Submenu
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
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 set point pressure (cut-
off pressure).
Result The Control voltage LED extinguishes. The machine is switched off and disconnected from the
power supply.
Switching off
Switching on
1. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
1. Attach an easily seen notice to the machine that warns of remote operation.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
or
Alarm message
An alarm shuts the machine down automatically. The red alarm LED flashes.
The system displays the appropriate message.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2.
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the yel‐
low warning LED flashes.
The system displays the appropriate message.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2.
The messages valid for your machine are dependent on how the individual machine is equipped.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.
Further information Detailed information for the various messages can be found in the service manual
SIGMA CONTROL 2.
10 Maintenance
10.1 Ensuring safety
Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 psig.
➤ Do not open or dismantle any valves.
Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Do not open the cabinet while the machine is switched on.
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
➤ Reset the maintenance interval counter as described in the SIGMA CONTROL 2 operating
manual.
➤ 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 Lu‐ 6,000 Hours 8,000 Hours
bricant
S–680 ISO 68 Synthetic Lu‐ 6,000 Hours 8,000 Hours
bricant
FG–460 ISO 46 Food Grade 2,000 Hours 3,000 Hours
Synthetic Fluid
1. Carefully remove the ventilation grill and take out the filter mat.
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. Insert the filter mat in the frame and latch in the ventilation grill.
10.4 Option K1
Cooler maintenance
Regularly clean the cooler. This ensures reliable cooling of the machine and the compressed air.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.
Clogged coolers are indicative of unfavorable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the engines resulting in increased
wear and tear.
➤ Have the authorized KAESER service representative clean the cooling air ducts.
Clean cooler/radiator
10.5 Option K2
Water-cooling Maintenance
Cooler clogging causes overheating and machine damage.
➤ Observe the airend discharge temperature to detect any tendency to rise.
Check the cooler regularly for leaks and contamination. Frequency of checking is dependant on the
characteristics of the cooling water.
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.
Cleaning
➤ An authorized KAESER Service representative should clean the cooler when the airend dis‐
charge temperature is 10 K above the annual average.
10.6 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat helps to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer ensured.
Removal
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out 5 times.
Refitting
10.7.1 Option W1
External heat recovery system
➤ Have the external heat recovery system checked annually by an authorized KAESER service
representative.
Material Spares
Drive motor
Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are factory-filled with grease.
Apply the quantity of grease as stated on the motor nameplate.
Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are factory-filled with grease.
Apply the quantity of grease as stated on the motor nameplate.
➤ Have the fan motor bearings checked by an authorized KAESER service representative.
1. Remove the securing screws and take off the safety screen.
2. Turn the coupling my hand and look for damage or color change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Excessive noise is caused when the safety relief valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear hearing protection.
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. Log on to SIGMA CONTROL 2 with access level 2.
4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. Risk of burns due to released cooling oil and compressed air when blowing off
the safety relief valve!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear eye protection.
6. End the test as soon as the safety relief valve blows off or working pressure exceeds the acti‐
vating pressure of the safety relief valve by nearly 14.7 psig.
7. If necessary, vent the machine and replace the defective safety relief valve.
8. Deactivate the test function
9. Open the user's shut-off valve between the machine and the air distribution network.
Precondition The machine has been running at least 5 minutes under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/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. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/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. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
A sticker on the oil separator tank specifies the type of oil used.
1. Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
➤ Depressurize all pressurized components and enclosures.
2. The machine could be damaged by unsuitable oil!
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
3. Slowly unscrew the filler plug 4 .
4. Top up to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.
1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air distribution network.
3. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.
4. Switch off the machine and check visually for leaks.
➤ Always change the oil filter and oil separator cartridge when changing the oil.
➤ Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to
adjust the airend discharge temperature to suit operating conditions.
Compressed air helps to expel the oil. This compressed air can be taken either from the compres‐
sor itself or from an external source.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.
Oil changing with help from internal pressure Oil change with an external compressed air
source
Machine has been running at least 5 minutes The supply disconnecting device is switched off,
under LOAD. the device is locked off,
The machine is fully vented, the absence of voltage has been verified.
the pressure gauge on the oil separator tank The machine is fully vented,
reads 0 psig. the pressure gauge on the oil separator tank
1. Close the shut-off valve 10 in the venting reads 0 psig.
line. An external source of compressed air is availa‐
2. Select IDLE running. ble.
3. Start the machine and watch the oil separa‐ 1. Close the shut-off valve 10 in the venting
tor tank pressure gauge 2 until it reads 43– line.
73 psig. 2. With the shut-off valve closed, insert the
4. Switch off and lock out the power supply male hose fitting 6 into the hose cou‐
disconnecting device and verify the absence pling 3 .
of any voltage. 3. Connect the maintenance hose to the exter‐
5. Wait at least 2 minutes to allow the oil to nal air supply.
flow back to the separator tank. 4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 43–
73 psig.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Option W1 Draining the oil from the external heat recovery system
If the machine is connected to an external heat recovery system, drain the oil from the heat ex‐
changer at a suitable point.
Option W2/W3 Draining cooling oil from the internal heat exchanger
1. Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
➤ Depressurize all pressurized components and enclosures.
2. Slowly open the filler plug 4 (Fig. 34).
3. Fill with cooling oil.
4. Check the filler plug and ring seal for damage and screw the plug back in again.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air distribution 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.
➤ Dispose of used oil in accordance with environment protection regulations.
Material Spares
Cooling oil receptacle
1. Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
➤ Depressurize all pressurized components and enclosures completely.
2. Unscrew the oil filter counter-clockwise, catch oil spillage and dispose of in accordance with
environmental protection regulations.
3. Lightly oil the new oil filter gasket.
4. The oil filter is turned clockwise 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 air distribution network.
3. Switch on the power supply and reset the maintenance interval counter.
4. After approx. 10 minutes of operation: Check the cooling oil level and top off if necessary.
5. Switch off the machine and check visually for leaks.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.
Material Spares
Cleaning cloth
1. Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
➤ Depressurize all pressurized components and enclosures completely.
2. Unscrew the fitting 1 and carefully put the parts to one side, then pull out the copper pipe from
the dirt trap 2 .
3. Loosen the fitting 3 and disconnect the air pipe 4 completely if necessary.
4. Remove the cover fixing screws 5 and carefully remove the cover 8 .
5. Take out the old oil separator cartridge 7 together with the gaskets 6 and dispose of accord‐
ing to environmental protection regulations.
6. Clean all sealing faces.
7. Insert the new oil separator cartridge with gaskets and screw down the cover 8 .
8. Renew the O-ring and strainer in the dirt trap 2 .
9. Secure the air pipe 4 with a new self-locking nut.
See chapter 10.19 "Assembly of flexible pipe connections".
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air distribution network.
3. Switch on the power supply and reset the maintenance interval counter.
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.
Precondition The pipe 1 must be de-burred and the sealing face clean and undamaged.
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spare parts or operating materials.
➤ Use only original KAESER parts and operating fluids/materials.
➤ Have an authorized KAESER service representative carry out regular maintenance.
Machine
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion 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 overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact an au‐
thorized KAESER service representative for more information.
Material Desiccant
Plastic sheeting
Wooden crate
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
12.4 Transport
12.4.1 Safety
Weight and center of gravity determine the most suitable method of transportation. The center of
gravity is shown in the drawing in chapter 13.3.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only using a forklift truck or lifting gear and only by personnel trained in the safe trans‐
portation of loads.
➤ Drive the forks completely under the machine or pallet and lift carefully.
➤ Please consult with KAESER if you have questions to the appropriate lifting gear.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove old 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