Service Manual: Screw Compressor ASD

Service Manual
Screw Compressor
ASD
9_5712 06 E
Manufacturer:
KAESER KOMPRESSOREN GmbH

96450 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SASD 1.00 en
Contents
1 Regarding this document

1.1 Using the Document ......................................................................................................... 1
1.2 Additional Documents ...................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and Identification ............................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Other instructions and symbols .......................................................................... 2
2 Technical Specification
2.1 Nameplate ........................................................................................................................ 3
2.2 Options ............................................................................................................................. 3
2.3 Weight .............................................................................................................................. 3
2.4 Temperature ..................................................................................................................... 4
2.5 Ambient Conditions .......................................................................................................... 4
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure ........................................................................................................................... 5
2.8 Delivery ............................................................................................................................ 6
2.9 Cooling Oil Recommendation .......................................................................................... 6
2.10 Cooling Oil Charge ........................................................................................................... 7
2.11 Motors and Power ............................................................................................................ 8
2.11.1 Drive motor ......................................................................................................... 8
2.11.2 Fan motor ........................................................................................................... 8
2.12 Sound Pressure Level ...................................................................................................... 9
2.13 Power Supply ................................................................................................................... 9
2.14 Power supply specifications ............................................................................................. 10
2.14.1 Mains frequency: 50 Hz ...................................................................................... 10
2.14.2 Mains frequency: 60 Hz ...................................................................................... 11
2.15 Heat Recovery ................................................................................................................. 11
2.15.1 Prepared for external heat recovery ................................................................... 11
2.15.2 Internal heat recovery ......................................................................................... 12
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 14
3.2 Specified Use ................................................................................................................... 14
3.3 Improper Use ................................................................................................................... 14
3.4 User's Responsibilities ..................................................................................................... 14
3.4.1 Observe statutory and universally accepted regulations .................................... 14
3.4.2 Qualified personnel ............................................................................................. 15
3.4.3 Inspection Schedules and Accident Prevention Regulations ............................. 15
3.5 Dangers ............................................................................................................................ 16
3.5.1 Safely Dealing with Sources of Danger .............................................................. 16
3.5.2 Safe Machine Operation ..................................................................................... 18
3.5.3 Organisational Measures .................................................................................... 19
3.5.4 Danger Areas ...................................................................................................... 19
3.6 Safety Devices ................................................................................................................. 19
3.7 Safety Signs ..................................................................................................................... 20
3.8 In Emergency ................................................................................................................... 21
3.8.1 Fire fighting ......................................................................................................... 21
3.8.2 Remove any cooling oil from your person. ......................................................... 21
3.9 Warranty ........................................................................................................................... 21
3.10 Environmental Protection ................................................................................................. 22
4 Design and Function
4.1 Enclosure ......................................................................................................................... 23
4.2 Functional Description of the Machine ............................................................................. 23
4.3 Floating relay contacts ..................................................................................................... 24
Service Manual Screw Compressor

9_5712 06 E ASD i
Contents
4.4 Options ............................................................................................................................. 25

4.4.1 Machine mountings ............................................................................................. 25
4.4.2 Optional Filter Monitoring Set ............................................................................. 25
4.4.3 Cooling air filter mat ............................................................................................ 25
4.4.4 Heat Recovery .................................................................................................... 25
4.5 Operating and Control Modes .......................................................................................... 26
4.5.1 Operating modes of the machine ........................................................................ 26
4.5.2 Control Modes .................................................................................................... 26
4.6 Safety Devices ................................................................................................................. 27
4.7 SIGMA CONTROL Keys and Indicators .......................................................................... 28
5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 30
5.2 Installation Conditions ...................................................................................................... 30
5.2.1 Place of installation and distances ...................................................................... 30
5.2.2 Ensure adequate ventilation. .............................................................................. 31
5.2.3 Exhaust duct design ........................................................................................... 31
5.3 Operating the Machine in an Air System. ......................................................................... 32
6 Installation
6.1 Safety ............................................................................................................................... 33
6.2 Reporting Transport Damage ........................................................................................... 33
6.3 Making the Compressed Air Connection .......................................................................... 33
6.4 Making the Power Supply Connection ............................................................................. 34
6.5 Options ............................................................................................................................. 35
6.5.1 Ânchoring the machine ....................................................................................... 35
6.5.2 Connecting the Heat Recovery System .............................................................. 35
7 Initial Start-up
7.1 Safety ............................................................................................................................... 37
7.2 Instructions to be Observed before before Every Start-Up .............................................. 37
7.3 Checking Installation and Operating Conditions .............................................................. 38
7.4 Setting the Overload Protection Cut-Out .......................................................................... 38
7.5 Setting the Motor Overload Protection Switch ................................................................. 39
7.6 Pouring Cooling Oil into the Airend .................................................................................. 39
7.7 Check Direction of Rotation ............................................................................................. 40
7.8 Starting the Machine for the First Time ............................................................................ 40
7.9 Setting the Setpoint Pressure .......................................................................................... 41
7.10 Changing the display language ........................................................................................ 41
8 Operation
8.1 Switching On and Off ....................................................................................................... 43
8.1.1 Switching on ....................................................................................................... 43
8.1.2 Shutdown ............................................................................................................ 43
8.2 Switching Off in an Emergency and Switching On again ................................................. 44
8.3 Remote On and Off Switching .......................................................................................... 44
8.4 Switching On and Off with the Clock ................................................................................ 45
8.5 Acknowledging Alarm and Warning Messages ................................................................ 46
9 Fault Recognition and Rectification
9.1 Basic Information ............................................................................................................. 48
9.2 Alarm Messages (machine shutdown) ............................................................................. 48
9.3 Warning Messages (yellow LED lights) ............................................................................ 51
9.4 Other Faults ..................................................................................................................... 55
10 Maintenance
10.1 Safety ............................................................................................................................... 56

ii ASD 9_5712 06 E
Contents
10.2 Maintenance Schedule ..................................................................................................... 56

10.2.1 Logging maintenance work ................................................................................. 56
10.2.2 Resetting maintenance interval counters ............................................................ 57
10.2.3 Regular Maintenance Tasks ............................................................................... 57
10.2.4 Cooling Oil: Change Interval ............................................................................... 58
10.2.5 Regular service work .......................................................................................... 59
10.3 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 59
10.4 Cleaning or Replacing the Control Cabinet Filter Mats .................................................... 60
10.5 Cooler Maintenance ......................................................................................................... 61
10.6 Heat Recovery System Maintenance ............................................................................... 62
10.6.1 External heat recovery ........................................................................................ 62
10.6.2 Internal heat recovery ......................................................................................... 63
10.7 Air Filter Maintenance ...................................................................................................... 63
10.8 Motor Maintenance .......................................................................................................... 64
10.9 Checking the Coupling ..................................................................................................... 64
10.10 Checking the Pressure Relief Valve ................................................................................. 65
10.11 Checking the Excess Temperature Safety Shutdown Function ....................................... 66
10.12 Checking the Cooling Oil Level ........................................................................................ 66
10.13 Venting the Machine (depressurizing) .............................................................................. 67
10.14 Topping up the Cooling Oil ............................................................................................... 69
10.14.1 Venting the machine (depressurizing) ................................................................ 69
10.14.2 Topping up with cooling oil and trial run ............................................................. 70
10.15 Changing the Cooling Oil ................................................................................................. 71
10.16 Changing the Oil Filter ..................................................................................................... 75
10.17 Changing the Oil Separator Cartridge .............................................................................. 76
10.18 Document maintenance and service work. ...................................................................... 79
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 80
11.2 Ordering Consumable Parts and Operating Materials ..................................................... 80
11.3 SIGMA AIR SERVICE ...................................................................................................... 80
11.4 Service Addresses ........................................................................................................... 81
11.5 Spare Parts for Service and Repair ................................................................................. 81
12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation .................................................................................................. 84
12.2 Packing ............................................................................................................................ 84
12.3 Storage ............................................................................................................................. 84
12.4 Transporting ..................................................................................................................... 85
12.4.1 Safety .................................................................................................................. 85
12.4.2 Transporting with a forklift truck .......................................................................... 85
12.4.3 Transporting with a crane ................................................................................... 85
12.5 Disposal ........................................................................................................................... 86
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 87
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 93
13.3 Dimensional Drawing ....................................................................................................... 99
13.4 Electrical Diagram ............................................................................................................ 102

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Contents

iv ASD 9_5712 06 E
List of Illustrations
Fig. 1 Maximum relative humidity ......................................................................................................... 5

Fig. 2 Location of safety signs .............................................................................................................. 20
Fig. 3 Enclosure ................................................................................................................................... 23
Fig. 4 Machine layout ........................................................................................................................... 24
Fig. 5 Machine mountings .................................................................................................................... 25
Fig. 6 Cooling air filter mat (option K3) ................................................................................................. 25
Fig. 7 Internal heat recovery (option W2/W3) ....................................................................................... 26
Fig. 8 Keys ........................................................................................................................................... 28
Fig. 9 Indicators .................................................................................................................................... 29
Fig. 10 Recommended installation and dimensions [mm] ...................................................................... 31
Fig. 11 Compressed air connection ........................................................................................................ 34
Fig. 12 Connecting the heat recovery system ........................................................................................ 35
Fig. 13 Inlet valve filling port ................................................................................................................... 39
Fig. 14 Coupling ..................................................................................................................................... 40
Fig. 15 Label: Changing the display language ....................................................................................... 42
Fig. 16 Switching on and off ................................................................................................................... 43
Fig. 17 Switching off in an emergency ................................................................................................... 44
Fig. 18 Switching on and off in remote ................................................................................................... 45
Fig. 19 Switching on and off with the clock ............................................................................................ 46
Fig. 20 Acknowledging/resetting messages ........................................................................................... 47
Fig. 21 Cooling air filter mat ................................................................................................................... 60
Fig. 22 Control cabinet ventilation grill ................................................................................................... 61
Fig. 23 Cleaning the cooler .................................................................................................................... 62
Fig. 24 Air filter maintenance .................................................................................................................. 63
Fig. 25 Checking the coupling ................................................................................................................ 65
Fig. 26 Checking the cooling oil level ..................................................................................................... 67
Fig. 27 Venting the machine ................................................................................................................... 68
Fig. 28 Topping up the Cooling Oil ......................................................................................................... 69
Fig. 29 Changing the cooling oil, oil separator tank ............................................................................... 72
Fig. 30 Changing the cooling oil, oil cooler ............................................................................................. 73
Fig. 31 Changing the cooling oil, airend ................................................................................................. 74
Fig. 32 Changing the cooling oil, heat recovery system ......................................................................... 75
Fig. 33 Changing the oil filter .................................................................................................................. 76
Fig. 34 Changing the oil separator cartridge .......................................................................................... 77
Fig. 35 Transporting with a forklift truck ................................................................................................. 85
Fig. 36 Transporting with a crane ........................................................................................................... 86

9_5712 06 E ASD v

vi ASD 9_5712 06 E
List of Tables
Tab. 1 The levels of danger and their meaning ..................................................................................... 2

Tab. 2 Nameplate .................................................................................................................................. 3
Tab. 3 Options ....................................................................................................................................... 3
Tab. 4 Machine weight .......................................................................................................................... 4
Tab. 5 Temperature ............................................................................................................................... 4
Tab. 6 Ambient Conditions .................................................................................................................... 4
Tab. 7 Ventilation ................................................................................................................................... 5
Tab. 8 Pressure relief valve activating pressure (50 Hz) ....................................................................... 5
Tab. 9 Pressure relief valve activating pressure (60Hz) ........................................................................ 6
Tab. 10 Delivery (50 Hz) .......................................................................................................................... 6
Tab. 11 Delivery (60 Hz) .......................................................................................................................... 6
Tab. 12 Cooling Oil Recommendation ..................................................................................................... 6
Tab. 13 Cooling Oil Charge ..................................................................................................................... 7
Tab. 14 Cooling oil charge (option W1) ................................................................................................... 7
Tab. 17 Drive motor ................................................................................................................................. 8
Tab. 18 Drive motor rated speed (50 Hz) ................................................................................................ 8
Tab. 19 Drive motor rated speed (60Hz) ................................................................................................. 8
Tab. 20 Fan motor .................................................................................................................................. 8
Tab. 21 Sound Pressure Level ................................................................................................................ 9
Tab. 22 Connection details 200V/3/50Hz ................................................................................................ 10
Tab. 29 Heat capacity (option W1) .......................................................................................................... 12
Tab. 30 Water quality specification .......................................................................................................... 12
Tab. 31 Heat exchanger specification (option W2/W3) ........................................................................... 13
Tab. 32 Heat capacity (option W2/W3) .................................................................................................... 13
Tab. 33 Flow rate (option W2) ................................................................................................................. 13
Tab. 34 Flow rate (option W3) ................................................................................................................. 13
Tab. 35 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 16
Tab. 36 Danger Areas ............................................................................................................................. 19
Tab. 37 Safety Signs ............................................................................................................................... 20
Tab. 38 Operating modes under MODULATING control ......................................................................... 27
Tab. 39 Keys ........................................................................................................................................... 28
Tab. 40 Indicators .................................................................................................................................... 29
Tab. 41 Initial start-up after storage ......................................................................................................... 38
Tab. 42 Installation conditions checklist .................................................................................................. 38
Tab. 43 Machine identification ................................................................................................................. 45
Tab. 44 Remote control identification ...................................................................................................... 45
Tab. 45 Machine identification ................................................................................................................. 46
Tab. 46 Alarm messages and measures ................................................................................................. 48
Tab. 47 Warning messages ..................................................................................................................... 51
Tab. 48 Other faults and actions ............................................................................................................. 55
Tab. 49 Regular maintenance tasks ........................................................................................................ 58
Tab. 50 Cooling oil changing intervals ..................................................................................................... 59
Tab. 51 Regular service work .................................................................................................................. 59
Tab. 52 Logged maintenance tasks ........................................................................................................ 79
Tab. 53 Consumable parts ...................................................................................................................... 80

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viii ASD 9_5712 06 E
1.1 Using the Document

1.1 Using the Document
The service manual is part of the machine. It describes the machine as it was at the time of first
delivery after manufacture.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are entered in the manual.
➤ Enter details from the machine nameplate and individual items of equipment in the table in chap‐
ter 2.
1.2 Additional Documents

Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
■ Certificate of acceptance / operating instructions for the pressure vessel.
■ Manufacturer's declaration / declaration of conformity in accordance with applicable directives.
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.
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.
1.4 Symbols and Identification

1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
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.

9_5712 06 E ASD 1
1.4 Symbols and Identification
➤ Always read and comply with warning instructions.
Signal word Meaning Consequences of non-observance

DANGER Warns of an imminent threat of danger Death or serious injury may result
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situation Light injuries or material damage are possi‐
ble
Tab. 1 The levels of danger and their meaning
1.4.2 Other instructions and symbols

This symbol refers to particularly important information.
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.
Further information Here, your attention is drawn to further topics.

2 ASD 9_5712 06 E
2.1 Nameplate
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine:

■ above the cooler,
or
■ on the rear of the machine.
➤ Enter the data from the nameplate here as a reference:
Attribute Data
Model
Material no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature
Tab. 2 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference
Option Option code Exists?

Modulating control C1
Filter monitoring option package C2
Machine mountings H1
Cooling air filter mat K3
Transformer power supply T2
Prepared for heat recovery W1
Heat recovery ΔT=25 K W2
Heat recovery ΔT=55 K W3
Tab. 3 Options
2.3 Weight
The weight given is the maximum. The actual weights of individual machines are dependent on
equipment fitted.

9_5712 06 E ASD 3
2.4 Temperature
ASD 32 ASD 37 ASD 47 ASD 57

Weight [kg] 600 680 690 740
Tab. 4 Machine weight
2.4 Temperature
Minimum cut-in tempera‐ 3 3 3 3
ture [°C]
Typical airend discharge 75–100 75–100 75–100 75–100
temperature during opera‐
tion [°C]
Maximum airend dis‐ 110 110 110 110
charge temperature (auto‐
matic safety shut-down)
[°C]
Tab. 5 Temperature
2.5 Ambient Conditions

Maximum altitude AMSL* 1000 1000 1000 1000
[m]
Permissible ambient tem‐ 3–45 3–45 3–45 3–45
perature [°C]
Cooling air temperature 3–45 3–45 3–45 3–45
[°C]
Inlet air temperature [°C] 3–45 3–45 3–45 3–45
Maximum relative humidi‐ see figure 1 see figure 1 see figure 1 see figure 1
ty of inlet air
* Higher altitudes are permissible only after consultation with the manufacturer
Tab. 6 Ambient Conditions

4 ASD 9_5712 06 E
2.6 Ventilation
Fig. 1 Maximum relative humidity

T Inlet air temperature [°C]
H Maximum relative humidity of inlet air [%]
2.6 Ventilation
The values given are minimum guide values.

Inlet aperture Z see fig‐ 0.5 0.6 0.7 0.8
ure 10 [m2]
Forced ventilation with ex‐ 7000 8000 10000 12000
haust fan:
Flow rate [m3/h] at 100 Pa
Exhaust duct: 650 x 650 650 x 650 650 x 650 650 x 650
Dimensions [mm]
Tab. 7 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
Pressure relief valve activating pressure at 50 Hz [bar]
Maximum working pres‐ ASD 32 ASD 37 ASD 47 ASD 57

sure [bar]
8 10 10 10 10
11 14 14 14 14
15 16 16 16 16
Tab. 8 Pressure relief valve activating pressure (50 Hz)

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2.8 Delivery
Pressure relief valve activating pressure at 60 Hz [bar]

sure [bar]
8.5 10 10 10 10
12 14 14 14 14
15 16 16 16 16
Tab. 9 Pressure relief valve activating pressure (60Hz)
2.8 Delivery
Delivery [m3/min] at 50 Hz mains frequency

sure [bar]
8 3.2 3.9 4.6 5.5
11 2.7 3.1 3.8 4.4
15 2.1 2.6 2.9 3.6
Tab. 10 Delivery (50 Hz)
Delivery [m3/min] at 60 Hz mains frequency

sure [bar]
8.5 3.2 3.7 4.6 5.4
12 2.5 3.1 3.6 4.5
15 2.1 2.4 3.0 3.5
Tab. 11 Delivery (60 Hz)
2.9 Cooling Oil Recommendation

A sticker showing the type of oil used is located near the oil separator tank filler.
Information on ordering cooling oil is found in chapter 11.
SIGMA FLUID
S–460 MOL FG–460/FG–680
Description Silicone-free Mineral oil Synthetic oil
synthetic oil
Application Standard oil for all applica‐ Standard oil for all Specifically for applications
tions except in connection applications except where the compressed air
with foodstuffs. in connection with comes into contact with food‐
Particularly suitable for ma‐ foodstuffs. stuffs.
chines with a high duty cy‐ Particularly suitable
cle. for machines with a
low duty cycle.

6 ASD 9_5712 06 E
2.10 Cooling Oil Charge
SIGMA FLUID
S–460 MOL FG–460/FG–680
Approval — — USDA H–1, NSF
Approved for the manufac‐
ture of foodstuff packaging,
meat and poultry processing
and other food processing.
Viscosity at 40 °C 45 mm2/s 44 mm2/s 50.7/70.0 mm2/s
(D 445; ASTM Test) (DIN 51562–1) (D 445; ASTM Test)
Viscosity at 7.2 mm2/s 6.8 mm2/s 8.2/710.4 mm2/s
100 °C (D 445; ASTM Test) (DIN 51562–1) (D 445; ASTM Test)
Flash point 238 °C 220 °C 245 °C
(D 92; ASTM Test) (ISO 2592) (D 92; ASTM Test)
Density at 15 °C 864 kg/m3 — —
(ISO 12185)
Pour point −46 °C −33 °C —
(D 97; ASTM Test) (ISO 3016)
Demulsibility at 40/40/0/10 min — —
54 °C (D 1401; ASTM Test)
Tab. 12 Cooling Oil Recommendation
2.10 Cooling Oil Charge

Option K1 Air-cooling

Total charge [l] 16 16 16 16
Top-up quantity [l] 2 2 2 2
(minimum–maximum)
Tab. 13 Cooling Oil Charge
Option W1/W2/W3 Heat Recovery
The charge of cooling oil for machines with heat recovery is increased by the volume of oil in
the heat exchanger and connecting lines.
Option W1 ASD 32 ASD 37 ASD 47 ASD 57

Additional charge volume
[l]*
* Enter the volume required by your heat recovery system.
Tab. 14 Cooling oil charge (option W1)
Option W2

9_5712 06 E ASD 7
2.11 Motors and Power

Additional charge volume 1.1 1.7 1.7 1.7
[l]
Option W3 ASD 32 ASD 37 ASD 47 ASD 57

Additional charge volume 1.1 1.7 1.7 1.7
[l]
2.11 Motors and Power

2.11.1 Drive motor
Rated power [kW] 18.5 22.0 25.0 30.0
Enclosure protection IP 55 IP 55 IP 55 IP 55
Tab. 17 Drive motor
Rated speed at 50 Hz [rpm]

sure [bar]
8 2940 2945 2945 2945
11 2940 2945 2945 2945
15 1470 2945 2945 2945
Tab. 18 Drive motor rated speed (50 Hz)
Rated speed at 60 Hz [rpm]

sure [bar]
8.5 3550 3545 3550 3550
12 1780 3545 3550 3550
15 1780 1780 3550 3550
Tab. 19 Drive motor rated speed (60Hz)
2.11.2 Fan motor

Rated power [kW] 0.30/0.50* 0.30/0.50* 0.40/0.50* 0.55/0.55*
* 60Hz

8 ASD 9_5712 06 E
2.12 Sound Pressure Level

Rated speed [rpm] 910 910 910 910
1080* 1080* 1080* 1080*
Enclosure protection IP 54 IP 54 IP 54 IP 54
* 60Hz
Tab. 20 Fan motor
2.12 Sound Pressure Level

Operational state
■ Nominal volume flow
■ Nominal pressure
Measurement conditions
■ Free-field measurement to CAGI/PNEUROP PN8 NTC 2.3
■ Measurement distance: 1 m
Sound pressure level [dB ASD 32 ASD 37 ASD 47 ASD 57

(A)]
at 50 Hz 65 66 66 69
at 60 Hz 66 67 67 69
Tab. 21 Sound Pressure Level
2.13 Power Supply

Basic requirements
The machine is designed for a power supply conforming to EN 60204–1 (IEC 60204–1), section 4.3.
In the absence of other user-specified conditions, the limits laid down in this standard must be adhered
to.
It is recommended that the supplier and user confer and agree on the basis of the EN 60240–1, Annex
B.
The machine requires a symmetrical three-phase power supply.
In a symmetrical three-phase supply the phase angles and voltages are all the same.
The machine may only be operated from an earthed TN or TT three-phase supply.
Connection to an IT supply is not permitted without taking further measures (earth leak detection,
etc.).
Further requirements
Demands on a three-phase supply for a machine with the following equipment:

■ Variable frequency drive (SFC)
■ Refrigeration dryer powered from a transformer
This machine may only be supplied from an earthed TN or TT three-phase supply in which the neutral
point is earthed.

9_5712 06 E ASD 9
2.14 Power supply specifications
The machine may not be connected to a three-phase supply in which one of the phases is earthed,
as this can lead to dangerous voltage surges.
Connection to an IT supply is not permitted without further measures being taken (earth leak detection,
specially designed frequency converter, etc.).
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.
2.14 Power supply specifications

The following supply cable conductor cross sections (copper multicore) and fusing (slow-blow
class gL) are selected according to German DIN VDE 0100–430 (IEC 60364–4–43 and IEC 60364–
4–473) and DIN VDE 0298-4 standards for 30 °C ambient temperature and wiring type C.
Electrical connection data, in some cases, depends the maximum working pressure of the ma‐
chine. These are shown in brackets().
➤ The conductor cross-sections should be changed accordingly if other conditions prevail.
Other conditions would include:

■ higher temperature
■ other cable laying method
■ cable lengths >50 m
2.14.1 Mains frequency: 50 Hz

Rated power supply 200V±10%/3/50Hz

Mains fusing [A] 100 100 125 160
Supply cable [mm2] 4x35 4x35 4x50 4x70
Current drawn [A] 68 / 78 (15) 83 101 122
Tab. 22 Connection details 200V/3/50Hz
Rated power supply: 230V±10%/3/50Hz

Mains fusing [A] 80 100 100 125
Current drawn [A] 60 / 69 (15) 72 90 105

Mains fusing [A] 50 50 63 80
Current drawn [A] 34 / 39 (15) 42 52 61

10 ASD 9_5712 06 E
2.15 Heat Recovery
2.14.2 Mains frequency: 60 Hz


Mains fusing [A] 80 (8.5) / 100 100 125 125
Supply cable [mm2] 4x20 (8.5) / 4x35 4x35 4x50 4x50
Current drawn [A] 62 (8.5) / 71 81 / 82 (15) 92 106

Current drawn [A] 38 (8.5) / 42 49 56 64

Current drawn [A] 33 (8.5) / 37 41 / 43 (15) 48 56

Current drawn [A] 31 (8.5) / 36 40 / 41 (15) 46 53
2.15 Option W1/W2/W3

Heat Recovery
2.15.1 Option W1
Prepared for external heat recovery
All connections are provided to accommodate an external heat exchanger.
The quality of the heat transfer medium and its required flow rate depend on the type of heat
exchanger used.

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2.15 Heat Recovery
Maximum heat capacity ASD 32 ASD 37 ASD 47 ASD 57

available
[kW] 16.4 19.3 23.9 27.6
[MJ/h] 59 69 86 99
[kcal/h] 14101 16578 20567 23732
Tab. 29 Heat capacity (option W1)
2.15.2 Option W2/W3

Internal heat recovery
Generally water is used as the heat transfer medium. The water must meet the specification given
below in order not to damage the heat exchanger.
➤ Consult KAESER Service if you wish to use a different heat transfer medium.
Water quality 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
Tab. 30 Water quality specification

12 ASD 9_5712 06 E
2.15 Heat Recovery
Heat exchanger specification

Material 1.4401 1.4401 1.4401 1.4401
Braze Copper (Cu) Copper (Cu) Copper (Cu) Copper (Cu)
Maximum working pres‐ 10 10 10 10
sure [bar]
(heat transfer medium)
Max. permissible dis‐ 100 100 100 100
charge temp. [ °C]
Pressure drop [bar] <0,1 <0,1 <0,1 <0,1
Unsuitable heat transfer Seawater
media Consult KAESER about water types.
Tab. 31 Heat exchanger specification (option W2/W3)
Heat capacity
Maximum heat capacity ASD 32 ASD 37 ASD 47 ASD 57

available
[kW] 16.4 19.3 23.9 27.6
[MJ/h] 59 69 86 99
[kcal/h] 14101 16578 20567 23732
Tab. 32 Heat capacity (option W2/W3)
Option W2 Flow rate for heating from 45 °C to 70 °C (ΔT = 25K)

Flow rate [m3/h] 0.56 0.66 0.82 0.95
Tab. 33 Flow rate (option W2)
Option W3 Flow rate for heating from 15 °C to 70 °C (ΔT = 55K)

Flow rate [m /h]
3 0.25 0.30 0.37 0.43
Tab. 34 Flow rate (option W3)

9_5712 06 E ASD 13
3.1 Basic Information

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ Danger to life and limb of the operator or third parties.
■ Impairments to the machine and other material assets.
DANGER
Disregard of 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.
3.2 Specified Use

The machine is intended solely for industrial use in generating compressed air. Any other use is
incorrect and does not comply with requirements. The manufacturer is not liable for any resulting
damages. The risk involved in such incorrect use is taken solely by the user.
➤ Keep to the specifications listed in this service manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated for such.
➤ Do not use compressed for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated for this.
3.3 Improper Use

➤ Never direct compressed air at persons or animals.
➤ Cooling air, warmed after passing through the machine, may be used for heating purposes but
only when it poses no health risk to humans or animals. If necessary, hot cooling air should be
treated by suitable means.
➤ Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are applied.
3.4 User's Responsibilities

3.4.1 Observe statutory and universally accepted regulations
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.

14 ASD 9_5712 06 E
3.4 User's Responsibilities
3.4.2 Qualified personnel

These are people who, by virtue of their training, knowledge and experience as well as their knowl‐
edge of relevant regulations can assess the work to be done and recognise the possible dangers
involved.
Authorised operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the service manual
relevant to operation,
■ have received adequate training and authorisation to operate electrical and compressed air de‐
vices.
■ Additional qualifications for compressors with refrigeration dryers:
─ Adequate training and authorisation ton refrigeration devices.
Authorised installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ have read, are conversant with and adhere to the safety instructions and sections of the service
manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
■ are able to recognise the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ have received adequate training and authorisation for the safe installation and maintenance on
this equipment.
■ Additional qualifications for compressors with refrigeration dryers:
─ fully conversant with the safety concepts and regulations concerning refrigeration devices,
─ must be able to recognise the possible dangers of refrigeration devices and take appropriate
measures to safeguard persons and property.
➤ Ensure that operating, installation and maintenance personnel are qualified and authorised to
carry out their tasks.
3.4.3 Inspection Schedules and Accident Prevention Regulations

The machine is subject to local inspection schedules.
Examples German inspection schedules
➤ Carry out recurring inspections to BGR 500, chapter 2.11:

The user must ensure that the machine's safety devices are checked for function as required or
at least annually.
➤ Carry out oil changes to BGR 500, chapter 2.11.
The user must ensure that the compressor oil is changed as required or at least annually; the oil
change is to be documented. This requirement may be waived if an oil analysis proves that the
oil is still usable.

9_5712 06 E ASD 15
3.5 Dangers
➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in Para. 15.
Inspection Inspection interval Inspecting authority

Installation and equipment in‐ Before initial start-up Approved supervisory body
spection
Internal inspection every 5 years after installation or Competent person
the last inspection, (e.g. KAESER service represen‐
tative)
Strength test every 10 years after installation Competent person
or the last inspection, (e.g. KAESER service represen‐
tative)
Tab. 35 Inspection intervals according to Ordinance on Industrial Safety and

Health
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.
3.5.1 Safely Dealing with Sources of Danger

Information concerning the various forms of danger that can arise during machine operation are found
here.
Electricity
➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised 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 concernes work on components that could be under pressure.

16 ASD 9_5712 06 E
3.5 Dangers
➤ 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.
➤ 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.
Compressed air quality
➤ Never directly inhale compressed air.

➤ Use appropriate systems for air treatment before using the compressed air from this machine as
breathing air and/or for the processing of foodstuffs.
➤ Use foodstuff-compatible cooling oil whenever compressed air is to come into contact with food‐
stuffs.
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, pressure 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
➤ Avoid contact with hot components.

These include, for example, compressor airends or blocks, oil and compressed air lines, coolers,
oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
Noise
➤ Operate the machine only with full soundproofing.

➤ Wear hearing protection if necessary.
The pressure relief valve blowing off can be particularly loud.
Operating materials
➤ Strictly forbid fire, open flame and smoking.

➤ Follow safety regulations when dealing with lubricants and chemical substances.

9_5712 06 E ASD 17
3.5 Dangers
➤ Avoid contact with skin and eyes.

➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
➤ 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.
Conversion or modification of the machine
➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.
Extension or modification of the compressed air system
➤ Extension or modification of the compressor station:

Check the blow-off capacity of pressure relief valves on air receivers and compressed air lines
before installing any new machines.
➤ If the blow-off capacits is insufficient:
Install pressure relief valves with larger blow-off capacity.
3.5.2 Safe Machine Operation

Information on safe conduct when handling the machine is found here.
Transport
➤ Use suitable lifting gear that conforms to local safety regulations.

➤ Allow transport only by personnel trained in the safe movement of goods.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
Installation
➤ Install the machine in a suitable compressor room.

➤ 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 with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.

18 ASD 9_5712 06 E
3.6 Safety Devices
➤ Ensure that required ambient conditions are maintained with regard to:
■ ambient temperature and humidity,
■ clean inlet air with no damaging contaminants,
■ inlet air free of explosive or chemically unstable gases or vapours,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
➤ Do not position the machine in warm exhaust air from other machines.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
Decommissioning, storage, disposal
➤ Drain out fluids and dispose of according to environmental regulations.

These include, for example, compressor oil and cooling water.
➤ Give refrigerant only to authorised bodies for disposal.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organisational Measures

➤ Designate personnel and their responsibilities.
➤ Give clear instructions on reporting faults and damage to the machine.
➤ Give instructions on fire reporting and fire-fighting measures.
3.5.4 Danger Areas

The table gives information on the areas dangerous to personnel.
Only authorised personnel may enter these areas.
Activity Danger area Authorised personnel

Transport Within a 3 m radius of the machine. Installation personnel for transport prepa‐
ration.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 1 m radius of the machine and its
supply cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Tab. 36 Danger Areas
3.6 Safety Devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Check safety devices for correct function regularly.

9_5712 06 E ASD 19
3.7 Safety Signs
➤ Do not remove or obliterate labels and notices.

➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter4, section 4.6.
3.7 Safety Signs

The diagram shows the positions of safety signs on the machine. The table lists the various safety
signs used and their meanings.
Fig. 2 Location of safety signs
Item Sign Meaning

1 Danger of fatal injury from electric shock!
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no
voltage is present.
2 Hot surface!
Risk of burns caused by contact with hot components
➤ Do not touch the surface.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
3 Risk of serious lacerations or even severing of extremities (fingers) from rotating com‐
ponents.
➤ Operate the machine only with closed safety guards, access doors and panels.
➤ Switch off and lock out the power supply disconnecting device and check that no
voltage is present before opening any machine enclosure or guard.
4 Risk of injury caused by an automatic machine start!
➤ Switch off and lock out the power supply disconnecting device and check that no
voltage is present before opening any machine enclosure or guard.
5 Risk of fatal injury caused by dismantling valves (spring-loaded or under pressure)!
➤ Do not open or dismantle the valve.
➤ Call an authorized Service Technician if a fault occurs.

20 ASD 9_5712 06 E
3.8 In Emergency
Item Sign Meaning

6 Serious injury, particularly to the eyes, can result from foreign objects being thrown
out from rotating components.
➤ Do not allow anything to fall through the ventilation grille
➤ Do not work above the machine if it is switched on.
7 Incorrect oil levels can cause damage to the machine or excessive oil content in the
compressed air.
➤ Check the oil level regularly and correct as necessary.
Tab. 37 Safety Signs
3.8 In Emergency
3.8.1 Fire fighting
Suitable extinguishing agents
■ Foam
■ Carbon dioxide
■ Sand or earth
Unsuitable or unsafe extinguishing agents

■ Strong jet of water
1. Keep calm.
2. Give the alarm.
3. Switch off the power supply disconnecting device, if possible.
4. Move to safety:
■ warn persons in danger
■ help incapacitated persons
■ close the doors
5. Try to extinguish the fire if you have the skill to do so.
3.8.2 Remove any cooling oil from your person.

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

9_5712 06 E ASD 21
3.10 Environmental Protection
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorised modifications,
■ incorrect maintenance,
■ incorrect repair.
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.
3.10 Environmental Protection

➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
mental protection regulations.
➤ Observe relevant national regulations.
This applies particularly to parts contaminated with cooling oil.
➤ Do not allow cooling oil to escape to the environment or into the sewage system.

22 ASD 9_5712 06 E
4.1 Enclosure

4.1 Enclosure
Fig. 3 Enclosure
1 Control cabinet door
2 Latch
3 Panel (removable)
The enclosure, when closed, serves various functions:

■ sound insulation
■ protection against contact with components
■ cooling air flow control
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 Functional Description of the Machine

Functional description using an air-cooled machine as an example.

9_5712 06 E ASD 23
4.3 Floating relay contacts
Fig. 4 Machine layout

1 Inlet valve 6 Control cabinet
2 Minimum pressure/check valve 7 Oil separator tank
3 Drive motor 8 Air filter
4 Oil filter 9 Oil/air cooler
5 Airend
Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the rotors
themselves and between them and the airend casing. This direct cooling in the compression chamber
ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure within
the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve main‐
tains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pressure/
check valve 2 into the air cooler 9 . The minimum pressure/check valve ensures that there is always
a minimum internal air pressure sufficient to maintain cooling oil circulation in the machine.
The air cooler brings down the compressed air temperature of only 5 to 10 K above ambient. Most of
the moisture carried in the air is removed during this cooling process.
4.3 Floating relay contacts

Floating relay contacts are provided for the transfer of signals, messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

24 ASD 9_5712 06 E
4.4 Options
4.4 Options
The options available for your machine are described below.
4.4.1 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 5 Machine mountings
4.4.2 Optional Filter Monitoring Set

Sensors monitor the operational state of the filter. Indication is given as soon as maintenance is
required.
The following filters are monitored:

■ Air filter
■ Oil filter
■ Oil separator cartridge
4.4.3 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
Fig. 6 Cooling air filter mat (option K3)

1 Cooling air filter mat
4.4.4 Option W1/W2/W3

Heat Recovery
Option W1 Prepared for external heat recovery
Connections are provided and bridged.

An external heat recovery system can be retrofitted at any time.

9_5712 06 E ASD 25
4.5 Operating and Control Modes
Option W2/W3 Internal heat recovery
A plate-type heat exchanger is installed for internal heat recovery.
Fig. 7 Internal heat recovery (option W2/W3)

1 Plate-type heat exchanger
4.5 Operating and Control Modes

4.5.1 Operating modes of the machine
The machine operates in the following modes:
■ LOAD:
The inlet valve is open. The airend delivers compressed air to the air system.
The drive motor runs under full load.
■ IDLE:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the
air system. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.
The drive motor runs unloaded, with low power consumption.
■ STANDSTILL:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the
air system. The oil separator tank is vented.
The drive motor is stopped.
Option C1 ■ MODULATING CONTROL:
With the help of a control valve; the proportional controller, the opening and closing of the inlet
valve is continuously varied in relation to the actual air demand. The airend delivers compressed
air to the air system.
The loading and power consumption of the drive motor rises and falls with the air demand.
The control valve is factory set. Contact the KAESER service representative before changing the
settings.
4.5.2 Control Modes

Using the selected control mode, the controller switches the drive motor according to definite rules
(the control mode) between the various operating modes in order to compensate for air being drawn
off by consumers and maintain the machine's working pressure between the preset cut-in and cut-
out pressures.
SIGMA CONTROL can work in the following control modes:

■ DUAL

26 ASD 9_5712 06 E
4.6 Safety Devices
■ QUADRO
■ VARIO
Option C1 ■ MODULATING control
DUAL
In the DUAL control mode, the compressor 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 shorter the idle period setting, the sooner (and more frequently) the motor is stopped.
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 shorter these periods, the sooner (and more frequently) the motor stops.
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idle period
is automatically lengthened or shortened to compensate for higher or lower drive motor starting fre‐
quencies.
Option C1 MODULATING control
MODULATING control is based on the DUAL control mode. The difference to DUAL is that the air
delivery is continuously varied within the control range of the machine.
This control mode is not available on variable speed drive machines with a frequency convert‐
er (SFC).
Compressed air demand Operating modes

rises MODULATING CONTROL
LOAD
falls MODULATING CONTROL
IDLE
STANDSTILL
Tab. 38 Operating modes under MODULATING control
4.6 Safety Devices

The following safety devices are provided and may not be modified in any way:
■ EMERGENCY STOP button:
The EMERGENCY STOP button shuts down the machine immediately. The motor remains stop‐
ped. The pressure system is vented.

9_5712 06 E ASD 27
4.7 SIGMA CONTROL Keys and Indicators
■ Pressure relief valve:

The pressure relief valve protects the machine from excessive pressure. It is preset at the factory.
■ Door interlock switches:
The machine will stop automatically if a door or panel fitted with these safety interlocks is opened
or removed.
■ Enclosures and guards for moving parts and electrical connections:
These protect against accidental contact.
Fig. 8 Keys
Item Description Function

1 «ON» Switches on the machine.
The programmed operating mode is active.
2 «OFF» Switches the machine off.
3 «Clock» Switches clock control on and off.
4 «Remote control» Switches remote control on and off.
5 «LOAD/IDLE» Toggles the compressor between LOAD and IDLE operating
modes.
6 «DOWN» Scrolls down the menu options.
Reduces a parameter value.
7 «UP» Scrolls up the menu options.
Increases a parameter value.
8 «escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
Returns to the main menu when held down at least 10 seconds.
9 «enter» Only affects the value in the third line of the display.
Enters the selected menu option.
Exits the edit mode and saves.

28 ASD 9_5712 06 E

10 «Events and information» Displays the event memory.
Selection is possible from every menu.
Return with «esc» key.
11 «Reset» Signifies recognition of alarms and warning messages.
Resets the event memory (when permitted).
Tab. 39 Keys
Fig. 9 Indicators

12 Display field Alphanumeric display with 4 lines.
13 Alarm Flashes red when an alarm occurs.
Lights continuously when acknowledged.
14 Communication Lights red if communication via the Profibus interface is interrupted.
15 Warning Flashes yellow for:
■ maintenance work due,
■ warning messages
Lights continuously when acknowledged.

16 Controller power Lights green when the power supply to the controller is switched on.
17 LOAD Lights green when the compressor is running under LOAD.
18 IDLE Lights green when the compressor is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
19 Machine ON Lights green when the machine switched on.
20 Clock The LED lights when the machine is in clock control.
21 Remote control The LED lights when the machine is in remote control.
Tab. 40 Indicators

9_5712 06 E ASD 29
5.1 Safety

5.1 Safety
➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
➤ The machine is not explosion-proof:
Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure that required ambient conditions are maintained with regard to:
■ ambient temperature and humidity,
■ clean inlet air with no damaging contaminants,
■ inlet air free of explosive or chemically unstable gases or vapours,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
➤ Keep suitable fire extinguishing agents ready for use.
5.2 Installation Conditions

5.2.1 Place of installation and distances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult KAESER if they cannot be kept to.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.

30 ASD 9_5712 06 E
5.2 Installation Conditions
Fig. 10 Recommended installation and dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Cooling air inlet aperture
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 +3 °C 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.
5.2.2 Ensure adequate ventilation.

If the ventilation is insufficient, a dangerous vacuum can build up in the machine room.
➤ 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 machine room.
5.2.3 Exhaust duct design

The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by
the duct design. Any additional air resistance will reduce airflow and deteriorate machine cooling.

9_5712 06 E ASD 31
5.3 Operating the Machine in an Air System.
➤ Consult the KAESER service representative before deciding on:

■ the design of the exhaust air ducting
■ the intersection between the machine and the exhaust air duct
■ the length of the ducting
■ the number of duct bends
■ the design of flaps or shutters
Use only motorised ventilation flaps and louvers on variable frequency drive (SFC) machines.
Flaps or louvers that open through the pressure of the airflow against the force of gravity do not
open sufficiently at low cooling fan speeds.
Further information Further information on installation of exhaust air ducts can be found in chapter 13.3.
5.3 Operating the Machine in an Air System.

If the machine is supplying an air system, the system operating pressure may not exceed 16 bar.
When charging a fully vented air system there is generally a very high rate of airflow through the air
treatment devices. These cannot function correctly under such conditions. Air quality suffers.
To ensure the desired air quality when charging a vented air network, we recommend the installation
of an air main charging system.
➤ Consult KAESER for advice on this subject.

32 ASD 9_5712 06 E
6 Installation
6.1 Safety
6 Installation
6.1 Safety
Follow the instructions below for safe installation.
Warning instructions are always given before a potentially dangerous action.
Basic safety instructions
1. Follow the instructions in chapter 3 'Safety and Responsibility'.

2. Installation work may only be carried out by authorized personnel.
3. Before switching on, make sure that:
■ no one is working on the machine,
■ all access doors and panels are closed and secure.
Working on live components.
1. Work on electrical equipment may only be carried out by authorized electricians.

2. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
3. Check that there is no voltage on floating relay contacts.
Working on pressure systems
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 hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
4. Do not open or dismantle any valves.
Working on the drive system
1. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
2. Do not open the cabinet while the machine is switched on.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.
6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Making the Compressed Air Connection

Precondition The compressed air system is vented completely.

9_5712 06 E ASD 33
6 Installation
6.4 Making the Power Supply Connection
Fig. 11 Compressed air connection

1 Axial compensator or hose
2 Shut-off valve
WARNING
Serious injury or death can result from loosening or opening components under pressure.
1. A shut off valve must be installed by the user in the connection line.
2. Make the compressed air connection with an axial compensator or hose.
6.4 Making the Power Supply Connection

Precondition All three phases of the power supply are isolated,
the disconnect device is locked in the off position,
a check has been made that no voltage is present.
1. Have the power supply connected by authorized installation personnel or an authorized electri‐
cian only.
2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example) and in
national accident prevention regulations (BGV A2 in Germany). In addition, observe the regula‐
tions of the local electricity supplier.
3. Check the permissible disconnect time of overload protection cutouts should a fault arise.
4. Select supply cable conductor cross-sections 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 supply
voltage.
If not, change the tappings to suit the power supply voltage.
DANGER
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
7. Connect the machine to the power supply.
Further information The electrical diagram 13.4 contains further details of the power supply connection.

34 ASD 9_5712 06 E
6 Installation
6.5 Options
6.5 Options
6.5.1 Option H1
Ânchoring 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 W1/W2/W3

Connecting the Heat Recovery System
➤ Take the electrochemical series into consideration and choose suitable materials for con‐
nections.
➤ Keep the effect of pressure surge on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.
WARNING
Cooling oil in the heat transfer medium.
Oil may contaminate the medium if a leak occurs.
➤ Do not use the transfer medium as drinking water.
6.5.2.1 Option W1
Connecting the external heat recovery system
An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within
the compressor. Damage to the machine will follow.
➤ Consult KAESER on a suitable heat exchanger and expert installation.
➤ Carry out installation and connection of the heat exchanger in accordance with specifications
from KAESER and the exchanger manufacturer.
6.5.2.2 Option W2/W3

Connecting the internal heat recovery system
Fig. 12 Connecting the heat recovery system

A Outlet 12 Connection port with stopper
B Inlet 17 Pressure relief valve
10 Shut-off valve

9_5712 06 E ASD 35
6 Installation
6.5 Options
1. The user is to provide the following fittings:

■ dirt trap with max. 0.1 mm strainer mesh,
■ shut-off valves 10 and connection ports 12 for maintenance and venting,
■ pressure relief valve 17 to prevent build-up of excessive pressure.
Blowoff pressure and capacity are related to the user's installation design. The technical
specification of the heat exchanger must be taken into consideration.
2. Connect the supply lines and fittings
3. Open the shut-off valve 10 at the inlet A .
4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the heat
transfer medium.
5. Bleed the lines.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connection
ports.

36 ASD 9_5712 06 E
7 Initial Start-up
7.1 Safety
7 Initial Start-up
7.1 Safety
Instructions for Safe Initial Start-up of the Machine.
Warning instructions are always given before a potentially dangerous action.
1. Follow the instructions in chapter 3 'Safety and Responsibility'.

2. Have installation work carried out by authorized installation personnel only.
Working on live components
1. Have work on electrical equipment carried out by authorized electricians only.

2. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt‐
age is present.
age is present.

7.2 Instructions to be Observed before before Every Start-Up

Incorrect or improper start-up can cause injury to persons and damage to the machine.

9_5712 06 E ASD 37
7 Initial Start-up
7.3 Checking Installation and Operating Conditions
➤ Start-up may only be carried out by authorized installation and service personnel who have been
trained on this machine.
Special measures for initial start-up after storage
Storage period longer than Measure

12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorized KAESER serv‐
ice representative.
36 months ➤ Have the overall technical condition checked by an authorized
KAESER Service representative.
Tab. 41 Initial start-up after storage
7.3 Checking Installation and Operating Conditions

➤ Check and confirm all the items in the checklist before initially starting the machine.
To be checked See chapter Confirmed

➤ Are the operators fully conversant with safety regulations? –
➤ Have all the installation conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.4
➤ Does the power supply conform to the specifications on the nameplate? 2.1
➤ Are the power supply cable conductor cross-sections and fuse ratings 2.14
adequate?
➤ Have all electrical connections been checked for tightness? –
➤ (The check must be repeated after 50 operating hours).
➤ Is a shut-off valve fitted to compressed air outlet? 6.3
➤ Has the connection to the air system been made with a hose or axial 6.3
compensator?
➤ Is there sufficient cooling oil in the separator tank? 10.12
(cooling oil level indicator outside the red zone)
➤ Is there sufficient cooling oil in the airend? 7.6
➤ Is the machine firmly anchored to the floor? 6.5.1
(option H1)
➤ Are all access doors closed and latched and all removable panels in –
place and secured?
Tab. 42 Installation conditions checklist
7.4 Setting the Overload Protection Cut-Out

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

38 ASD 9_5712 06 E
7 Initial Start-up
7.5 Setting the Motor Overload Protection Switch
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 arithmetical
phase current.
➤ Check the overload protection cut-out setting.
The overload protection cut-out shuts the machine down despite being correctly set?
➤ Contact the KAESER Service representative.
7.5 Setting the Motor Overload Protection Switch

In direct on-line starting, the current for the fan motor is fed via the motor overload protection switch.
To prevent the overload protection switch from being triggered by voltage fluctuations, temper‐
ature influences or component tolerances, the setting can be higher than the motor rated current
(see motor nameplate).
➤ Check the motor overload protection switch setting.
The overload switch shuts the machine down despite being correctly set?
➤ Contact KAESER Service.
7.6 Pouring Cooling Oil into the Airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to pour a quantity of cooling oil into the airend.
A label showing the type of oil used is found near the oil separator tank filling port.
➤ Use the same type of oil.
Material 1 lCooling oil
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.
Fig. 13 Inlet valve filling port

1 Screw plug
2 Inlet valve
1. Unscrew the filler plug from the inlet valve.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.

9_5712 06 E ASD 39
7 Initial Start-up
7.7 Check Direction of Rotation
Fig. 14 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
1. Remove the safety screen 3 .

2. Turn the coupling 2 by hand in the direction indicated by the arrow 4 .
3. Replace the safety screen 3 .
7.7 Check Direction of Rotation

The machine is designed for a clockwise phase sequence.
Ideally, the direction of phase rotation should be measured with a phase sequence meter.
Alternatively, start the machine very briefly and observe the direction of rotation of the motor cooling
fan.
1. Check the direction of phase rotation with a phase sequence meter.
2. If the direction is incorrect, reverse the supply phases L1 and L2.
You have no phase sequence meter?
➤ Switch the machine on and off again the moment the drive motor begins to turn.
➤ Compare the direction of rotation of the motor with the arrows on the motor and the airend
casing.
➤ If the direction is incorrect, reverse supply phases L1 and L2.
7.8 Starting the Machine for the First Time

Precondition No personnel are working on the machine,
all access doors are closed,
all removable panels in place and secured.
1. Open the shut-off valve to the air system.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Power ON LED lights continuously.
3. If required:
Change the display language as described in chapter 7.10.
4. Press the «LOAD/IDLE» key.
The green IDLE LED lights continuously.

40 ASD 9_5712 06 E
7 Initial Start-up
7.9 Setting the Setpoint Pressure
5. Press the «ON» key.

The green Machine ON LED lights continuously and the machine runs up in IDLE. This ensures
that cooling oil is gently distributed throughout the machine.
6. After at least 1 minute in IDLE:
Press the «LOAD/IDLE» key.
The machine switches to LOAD and delivers compressed air.
➤ Keep an eye on the machine during the first few hours of operation to ensure that it is
operating correctly.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
7.9 Setting the Setpoint Pressure

The setpoint pressure p1 is factory set to the highest possible value.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure of
the air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To reduce the cycling (toggling) frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.
➤ Set the setpoint pressure as described in the SIGMA CONTROL operating instructions.
7.10 Changing the display language

The controller can display text messages in several languages. The display language can be changed
first during initial start-up.
A label explains how this is done with the help of icons.

9_5712 06 E ASD 41
7 Initial Start-up
7.10 Changing the display language
Fig. 15 Label: Changing the display language

1 If required: 5 Press «Enter» to enter language selection.
Unlatch the EMERGENCY STOP button. 6 Press the «UP» or «DOWN» keys as often as
2 If required: necessary to reach the required language.
Acknowledge alarm message. 7 Press «enter» to select the language.
3 Depress the «escape» key for 5 seconds to 8 Depress the «escape» key for 5 seconds to
change to the main menu. change to the main menu.
4 Press the «UP» key 8 times.
➤ Change the display language on SIGMA CONTROL as required.

42 ASD 9_5712 06 E
8 Operation
8.1 Switching On and Off
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.
Fig. 16 Switching on and off

1 Machine ON LED (green) 3 «OFF» key
2 «ON» key 8 Controller ON LED (green)
8.1.1 Switching on
Precondition No personnel are working on the machine,
all access doors and panels are closed and secure.
1. Switch on the power supply disconnecting device.

After the controller has carried out a self-test, the green Power ON LED lights continuously.
2. Press the «ON» key.
The green Machine ON LED lights continuously.
If a power failure occurs, the machine is not prevented from automatic re-starting.
It can start automatically again as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
out pressure).
8.1.2 Shutdown
1. Press the «LOAD/IDLE» key.
The machine switches to IDLE and the IDLE LED flashes.
2. After allowing the machine to IDLE for 20 seconds:
press the «OFF» key.
The Machine ONLED extinguishes.
The machine is ready for operation. The machine can now be started again.

9_5712 06 E ASD 43
8 Operation
8.2 Switching Off in an Emergency and Switching On again
3. Switch off and lock out the power supply disconnecting device.
The machine is switched off and isolated from the mains supply. The Controller ONLED extin‐
guishes.
8.2 Switching Off in an Emergency and Switching On again

The EMERGENCY STOP pushbutton is located below the control panel.
Fig. 17 Switching off in an emergency

9 EMERGENCY STOP pushbutton
Shutdown
➤ Press the EMERGENCY STOP pushbutton.

The pushbutton remains latched in.
The compressor's pressure system is vented and the machine is prevented from automatically
re-starting.
Switching on
Precondition The fault has been rectified
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.
8.3 Remote On and Off Switching

Precondition A remote control device is linked.

44 ASD 9_5712 06 E
8 Operation
8.4 Switching On and Off with the Clock
Fig. 18 Switching on and off in remote

1 «remote control» key
2 remote control LED
1. Attach an easily seen notice that warns of remote machine operation.
DANGER!
This machine is remotely controlled and can start automatically at any time.
Tab. 43 Machine identification
2. Label the starting device in the remote control centre as follows:
DANGER!
➤ Before starting, make sure that no one is working on the machine and that it can be safely started.
Tab. 44 Remote control identification
3. Press the «remote» key.

The remote LED lights. The machine can be remotely controlled.
8.4 Switching On and Off with the Clock

Precondition The clock is programmed.

9_5712 06 E ASD 45
8 Operation
8.5 Acknowledging Alarm and Warning Messages
Fig. 19 Switching on and off with the clock

1 «clock» key
2 clock key
1. Attach an easily seen notice warning of time-controlled operation:
DANGER!
This machine is time-controlled and can start automatically at any time.
Tab. 45 Machine identification
2. Press the «clock» key.

The clock LED lights. The machine is switched on and off by the clock.

Messages are displayed on the "new value" principle:
■ Message received: LED flashes
■ Message acknowledged: LED lights
■ Message gone: LED extinguished
or
■ Message received: LED flashes

■ Message gone: LED flashes
■ Message reset: LED extinguished

46 ASD 9_5712 06 E
8 Operation
Fig. 20 Acknowledging/resetting messages

10 warning (yellow) LED
11 alarm (red) LED
12 «acknowledge/reset» key
Alarm message
Precondition Fault has been rectified
➤ Reset the message with the «acknowledge/reset» key.

alarm LED extinguishes.
The machine is now ready to start again.
Warning message
Precondition The danger of an alarm is eliminated.

Maintenance has been carried out
➤ Reset the message with the «acknowledge/reset» key.

warning LED extinguishes.

9_5712 06 E ASD 47

The following tables are intended to assist in locating faults.
There are three types of fault:

■ Alarm: red LED flashes - see chapter 9.2.
■ Warning: yellow LED flashes - see chapter 9.3.
■ Other faults: no indication - see chapter 9.4.
The messages valid for your machine are dependent 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 authorised KAESER service representative.
9.2 Alarm Messages (machine shutdown)

Message Possible cause Remedy
blowoff prot. ↥ The activating pressure of the pres‐ Change the oil separator cartridge.
sure relief valve on the oil separator Open the shut-off valve in the vent‐
tank has been exceeded. ing line.
sh.cct.AI1 The connection between the sensor Check line and connections.
sh.cct.AI2 and the analog input is shorted.
AI3/AI4 error Line-break between the analog input Check line and connections.
and the sensor.
Short circuit to earth.
sh.cct AI5 The connection between the sensor Check line and connections.
sh.cct AI6 and the analog input is shorted.
AI7/AI8 error Line-break between the analog input Check line and connections.
and the sensor.
Short circuit to earth.
Model Machine model uncertain Call KAESER service representa‐
tive.
bus alarm The bus link from the Profibus DP in‐ Check line and settings.
terface is defective.
PD ↧ Package discharge (PD) temperature Call KAESER service representa‐
too low. tive.
PD -↥ Package discharge (PD) temperature Check the cooling oil level.
too high. Clean the cooler.
Check the fan motor.
DO0.6/DO0.7 I ↥ Short circuit in the line between the Check line and connections.
digital output and the consumer.
DO1.6/DO1.7 I ↥ Short circuit in the line between the Check line and connections.
digital output and the consumer.

48 ASD 9_5712 06 E

Airend rotation The drive motor is turning in the wrong Swap phase lines L1 and L2.
direction.
error: RS485–USS SFC machine with USS protocol: Check the connection between the
RS485 transmission frequency converter and
SIGMA CONTROL frequency convert‐ SIGMA CONTROL.
er faulty. Check configuration of the RS485.
Call KAESER service representa‐
tive.
ext. message 0 Customer specific: –
ext. message 1 no details possible.
ext. message 2
ext. message 3
ext. message 4
ext. message 5
back pressure Back pressure in the oil separator tank Check venting line.
caused by defective venting.
HT cell Fault in the high tension cell. Call KAESER service representa‐
tive.
V-belts ruptured The drive belts have parted during ma‐ Replace drive belts.
chine operation.
no press.buildup The machine produces no com‐ Check the machine for leaks.
pressed air. Check coupling / V-belts
The working pressure does not rise Call KAESER service representa‐
above 3.5 bar within a default period. tive.
condensate drain. The condensate drain is defective. Check the condensate drain.
coolingwater low Cooling water pressure is too low. Check cooling water supply.
Cooling water throttling valve:
check setting.
RD p ↥ The pressure switch for the refrigerant Keep ambient conditions within
compressor has activated. specified limits.
Clean the refrigerant condenser.
Clean the cooler.
RD T ↑ Temperature in the refrigeration dryer Ensure adequate ventilation.
too high. Clean the refrigerant condenser.
Clean the cooler.
Install an extractor fan.
fan M2 I ↥ Overload shutdown of the first fan mo‐ Investigate cause of shutdown.
tor. Reset overload trip.
tive.
fan M3 I ↥ Overload shutdown of the second fan Investigate cause of shutdown.
motor. Reset overload trip.
tive.

9_5712 06 E ASD 49

fan M4 I ↥ Overload shutdown of the third fan mo‐ Investigate cause of shutdown.
tor. Reset overload trip.
tive.
fan M7 I ↥ Overload shutdown of the control cab‐ Investigate cause of shutdown.
inet fan motor. Call KAESER service representa‐
tive.
motor I ↥ Overload shutdown of the compressor Investigate cause of shutdown.
drive motor. Change the oil separator cartridge.
tive.
motor T ↥ Drive motor overheated. Clean the motor.
Keep ambient conditions within
specified limits.
motor bearings Drive motor bearings overheated. Grease the motor bearings.
tive.
mains cont. on? Mains contactor not pulling in. Check mains contactor and wiring.
mains cont. off? Mains contactor not dropping out. Check mains contactor and wiring.
mains voltage ↧ 2nd power failure. Check power supply voltage.
Check the door interlock switch.
mains monitor Fault in mains power supply. Have the mains power supply
checked.
Emergency stop EMERGENCY STOP pushbutton Unlatch the pushbutton.
pressed.
OST dp ↥ Oil separator cartridge clogged. Change the oil separator cartridge.
OST T ↥ Maximum air temperature at the oil Check the line to the trip relay.
separator tank outlet is exceeded.
oil p ↓ The machine cannot switch to LOAD Check the oil circulation.
until the minimum oil pressure is Check the pressure switch, line and
reached. connection.
p-switch Customer specific: –
no details possible.
pRV ↥ The activating pressure of the pres‐ Change the pressure relief valve.
sure relief valve on the oil separator
tank has been exceeded.
FC Frequency converter faulty. Call KAESER service representa‐
tive.
SIGMA CONTROL T ↥ The maximum permissible Keep ambient conditions within
SIGMA CONTROL housing tempera‐ specified limits.
ture has been exceeded. Control cabinet:
check filter mats and fan.
Softstart Fault in the soft start equipment. Call KAESER service representa‐
tive.

50 ASD 9_5712 06 E
9.3 Warning Messages (yellow LED lights)

start T ↧ Airend discharge temperature (ADT) Keep ambient conditions within
too low. specified limits.
Ambient temperature: < +2 °C
T switch Customer specific: –
ADT ↓ The airend discharge temperature Call KAESER service representa‐
(ADT) did not reach the minimum val‐ tive.
ue required within the specified time.
ADT ↥ Maximum permissible airend dis‐ Keep ambient conditions within
charge temperature (ADT) exceeded. specified limits.
Clean the cooler.
Check the cooling oil level.
ADT dT/dt Airend discharge temperature (ADT) Check the cooling oil level.
rising too quickly. Call KAESER service representa‐
tive.
access doors Door open / interlocked panel re‐ Fit and secure all panels and close
moved while the machine is running. access doors.
Tab. 46 Alarm messages and measures

blowoff prot. ↑ The activating pressure of the pressure Change the oil separator cartridge.
relief valve will soon be reached. Open the shut-off valve in the venting
line.
bus alarm The bus link from the Profibus DP in‐ Check bus highway and plug.
terface is interrupted.
PD temperature ↓ Package discharge (PD) temperature Call KAESER service representative.
too low.
PD temperature ↑ Package discharge (PD) temperature Clean the cooler.
too high. Check the cooling oil level.
elect. equip. h ↥ The maintenance interval for checking Carry out the check and reset the main‐
electrical equipment and wiring has ex‐ tenance interval counter.
pired.
error: FEPROM Internal controller memory error. Call KAESER service representative.
error: RS 485–PP Wrong configuration or transmission Check the link/interface connections
error. between the two controllers.
Check maximum cable length and
screening.
1 master and 1 slave configured.
error SMS SMS can not be sent. Call KAESER service representative.

9_5712 06 E ASD 51

ext. message 0 Customer specific: –
ext. message 1 no details possible.
ext. message 2
ext. message 3
ext. message 4
ext. message 5
FC AI1 fault SFC machine: Call KAESER service representative.
Air system pressure sensor to AI1 de‐
fective.
FC MM Service SFC machine: Deactivate the service mode as soon
Service mode for frequency converter. as the frequency converter settings are
completed.
FC mains SFC machine: Check power supply.
Power supply failure to the frequency
converter.
annual maint Last maintenance was one year ago. Carry out the necessary maintenance
and reset the corresponding mainte‐
nance interval counter.
no press.buildup The compressor cannot build-up to Check for air leaks.
working pressure. Check the value for internal pressure
given in the <analog data> menu
against the reading on the oil separator
tank pressure gauge.
condensate drain The condensate drain is defective. Check the condensate drain and drain
line.
RD T ↓ Refrigeration dryer: Call KAESER service representative.
Compressed air temperature too low.
RD p ↓ Refrigeration dryer: Call KAESER service representative.
Pressure in the refrigerant circuit too
low.
Inlet pressure switched tripped.
RD p ↥ Refrigeration dryer: Keep ambient conditions within speci‐
Pressure in the refrigerant circuit too fied limits.
high. Clean the refrigerant condenser.
Pressure relief switch tripped.
Check the fan motor.
Call KAESER service representative.
bearing.maint. h ↥ The maintenance interval for greasing Grease the motor bearings.
the bearings has expired.
ext.load signal? Ambiguous external load signal: Check settings of the external control‐
Increased cut-out pressure exceeded. ler. Take into account pressure drops
The external load control has not across filters and dryers.
switched to idle (off load).
air filter dp ↑ Air filter clogged. Carry out air filter maintenance.
air filter dp ↥ Air filter clogged. Carry out air filter maintenance.
air filter h ↥ Maintenance interval for air filter check Check the air filter.
has elapsed.

52 ASD 9_5712 06 E

modem problem SIGMA CONTROL does not recognise Check the link between
the modem. SIGMA CONTROL and the modem.
motor T ↑ Drive motor overheating. Clean the motor.
Keep ambient conditions within speci‐
fied limits.
motor starts /h ↥ The permissible number of motor starts Extend the idle period.
was exceeded during the last 60 mi‐ Increase the capacity of air receiver.
nutes.
Increase the cross-section of piping be‐
tween compressor and air receiver.
motor starts /d ↥ The permissible number of motor starts Extend the idle period.
was exceeded during the last 24 hours. Increase the capacity of air receiver.
Increase the cross-section of piping be‐
tween compressor and air receiver.
bearingchange h ↥ The maintenance interval for checking Have the motor bearings checked by an
the bearings has expired. authorized KAESER service represen‐
tative.
system press. ↓ Air system pressure has fallen below Check air demand.
the "low" value. Check transducer connections and wir‐
Air consumption too high. ing.
Check the 'sys.press. low' warning set‐
ting.
system press. ↑ Air system pressure is above the Check for air leaks.
"sys.press. high" value. Check the 'sys.press. high' warning set‐
ting.
Check whether the machine switches
to LOAD.
mains voltage ↓ 1. Power failure: Check power supply.
The machine was re-started automati‐ Check the door interlock switch.
cally.
OS dp ↥ The pressure drop across the oil sepa‐ Change the oil separator cartridge.
rator cartridge has risen.
Oil separator cartridge clogged.
OS h ↥ The interval for the next oil separator Change the oil separator cartridge.
cartridge check has expired.
oil filter dp ↑ The pressure drop across the oil filter Change the oil filter.
has risen.
Oil filter clogged.
oil filter h ↥ The interval for the next oil filter check Change the oil filter.
has expired.
Oil level ↓ Cooling oil level too low. Top up the cooling oil.
oil T ↓ Cooling oil temperature too low. Check temperature switch, line and
connection.
Check the oil circulation.
Increase room temperature.

9_5712 06 E ASD 53

oil change h ↥ The interval for the oil change has ex‐ Change the cooling oil.
pired.
p-switch Customer specific: –
buffer battery Data retention battery is almost dis‐ Change the battery.
charged.
error: RAM Internal RAM defective. Call KAESER service representative.
oil content ↑ The oil content limit for pure air will soon Check the scavenge tube in the oil sep‐
be reached. arator cartridge.
Check the dirt trap strainer in the scav‐
enge line.
Check air treatment upstream of the
measuring point.
V-belt tension Belt tension is too low. Re-tension drive belts.
blt.coup.insp.h ↥ The maintenance interval for V-belt ten‐ Carry out a visual check.
sion / coupling inspection has expired. Re-tension drive belts.
start T ↓ ↓ The airend temperature is too low (< Keep ambient conditions within speci‐
−10 °C) for the machine to be operated. fied limits.
start T ↓ The airend temperature is too low (< Keep ambient conditions within speci‐
+2 °C). fied limits.
set output The 'set outputs' test function is activa‐ Stop the 'set output' mode.
ted.
T switch Customer specific: –
TRAP interrupt System message: Call KAESER service representative.
TRAP interrupt
ADT ↑ Airend discharge temperature has al‐ Clean the cooler.
most reached maximum. Check the cooling oil level.
Replace the oil filter.
Ensure adequate ventilation.
Keep surrounding temperature within
recommended limits.
access doors Doors opened with the machine stop‐ Close access doors.
ped.
Tab. 47 Warning messages

54 ASD 9_5712 06 E
9.4 Other Faults
9.4 Other Faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call KAESER service represen‐
compressed air. opening partially. tative.
Venting valve not closing. Call KAESER service represen‐
tative.
Leaks in the pressure system. Check pipework and connec‐
tions for leaks and tighten any
loose fittings.
Air consumption is greater than Check the air system for leaks.
the capacity of the compressor. Shut down the consumer(s).
Hose coupling or maintenance Remove coupling or mainte‐

hose still plugged into the quick- nance hose.
release coupling on the oil sep‐
arator tank.
Cooling oil runs out of the air fil‐ Oil level in the oil separator tank Drain off oil until the correct level
ter. too high. is reached.
Inlet valve defective. Call KAESER service represen‐
tative.
Compressor switches between Air receiver too small. Increase size of air receiver.
LOAD and IDLE more than twice Airflow into the compressed air Increase air pipe diameters.
per minute. network restricted. Check filter elements.
The differential between cut-in Check switching differential.
and cut-out pressure too is
small.
Cooling oil leaking into the floor Hose coupling or maintenance Remove coupling or mainte‐
pan. hose still plugged into the quick- nance hose.
release coupling on the oil sep‐
arator tank.
Oil cooler leaking. Call KAESER service represen‐
tative.
Leaking joints. Tighten joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Use SIGMA FLUID cooling oil.
high. Oil separator cartridge split. Change the oil separator car‐
tridge.
Oil level in the oil separator tank Drain off oil until the correct level
too high. is reached.
Oil return line clogged. Check dirt trap in the return line.
Tab. 48 Other faults and actions

9_5712 06 E ASD 55
10 Maintenance
10.1 Safety
10 Maintenance
10.1 Safety
Follow the instructions below to ensure safe machine maintenance.
Warning instructions are always given before a potentially dangerous task.
1. Follow the instructions in chapter 3 "Safety and Responsibility".

2. Maintenance work may only be carried out by authorized personnel.
Working on live components
1. Have work on electrical equipment carried out by authorized electricians only.

age is present.
age is present.

10.2 Maintenance Schedule

10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for average operating conditions.
➤ Maintenance tasks should be carried out more frequently where operating conditions are
unfavourable (e.g. dusty atmosphere) or when the equipment is in constant use.
➤ Adjust the maintenance intervals with regard to local installation and operating conditions.

56 ASD 9_5712 06 E
10 Maintenance
➤ Keep a log of all maintenance and repair work.

This enables the frequency of individual maintenance tasks and deviations from our recommen‐
dations to be determined.
Further information A prepared list is provided in chapter 10.18.
10.2.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters monitor
the operational state of major components. Necessary maintenance tasks are displayed on
SIGMA CONTROL.
Maintenance interval counters count down the operating hours to the next maintenance task.
Reset the counter to the original value once the task has been carried out.
Precondition Maintenance carried out,

service message acknowledged and
password level 4 activated.
1. Select the appropriate entry in the "Maintenance" menu.

2. Select 'reset' and 'y' and confirm with the «enter» key.
Further information Detailed information can be found in the SIGMA CONTROL operating instructions.
10.2.3 Regular Maintenance Tasks

The table below lists maintenance tasks required.

9_5712 06 E ASD 57
10 Maintenance
➤ Take note of the controller's service messages and carry out tasks punctually taking ambient and
operating conditions into account.
Interval Maintenance task See chapter

Weekly Check the cooling oil level 10.12
Control cabinet: 10.4
check the filter mat
Up to 1,000 h Check the air filter 10.7
Clean the cooler 10.5
Option K3: 10.3
clean the cooling air filter mat
SIGMA CONTROL dis‐ Check the coupling 10.9
play Change the air filter element 10.7
Up to 3,000 h
Option K3: 10.3
change the cooling air filter mat
Control cabinet: 10.4
change the filter mat
SIGMA CONTROL dis‐ Change the oil filter 10.16
play
Up to 6,000 h
At least annually
SIGMA CONTROL dis‐ Change the oil separator cartridge 10.17
play
Up to 6,000 h
At the latest every 3 years
Variable (see table 50) Change the cooling oil 10.15
Annually Check that all electrical connections are tight –
Check the pressure relief valve 10.10
Check the overheating safety shutdown function 10.11
Check the cooler for leaks 10.5
h = operating hours
Tab. 49 Regular maintenance tasks
10.2.4 Cooling Oil: Change Interval

Duty cycles and ambient conditions are important criteria for the number and length of the change
intervals.
KAESER Service will support you in determining suitable intervals and provide information on
the possibilities of oil analysis.
➤ Please observe national regulations regarding the use of cooling oil in oil-injected rotary screw
compressors.

58 ASD 9_5712 06 E
10 Maintenance
10.3 Cleaning or Renewing the Cooling Air Filter Mat
➤ Check operating conditions and adjust intervals as necessary; log the results in table 50 for future
reference.
Maximum permissible oil change interval

[operating hours/year]
SIGMA FLUID Favourable operating Unfavourable operat‐ My operating condi‐
conditions* ing conditions tions
PLUS / S-460 6 000**/2 4 000/1
MOL 3 000/1 2 000/1
FG–460/FG–680 3 000/1 2 000/1
FGH 3 000/1 2 000/1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Changing intervals of >6000 operating hours are not permissible without an oil analysis.
Tab. 50 Cooling oil changing intervals
10.2.5 Regular service work

The table below lists necessary service tasks.
➤ Only authorized KAESER Service Technicians should carry out service work.
➤ Carry out service tasks punctually taking ambient and operating conditions into account.
Interval Service task

Up to 12,000 h Check the valves
Up to 12,000 h, at the lat‐ Check the drive motor and fan motor bearings.
est every 3 years
Up to 36,000 h, at the lat‐ Check hose lines
est every 8 years
h = operating hours
Tab. 51 Regular service work
10.3 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat help to keep the cooler clean. If the filter mat is clogged, adequate cooling of the com‐
ponents is no longer ensured.
Material Warm water and household detergent

Spare parts (as required)
Precondition The machine is switched off.

9_5712 06 E ASD 59
10 Maintenance
10.4 Cleaning or Replacing the Control Cabinet Filter Mats
Fig. 21 Cooling air filter mat

1 Cooling air filter mat
2 Retaining frame
3 Fixing
Removal
1. Open the fixing 3

by turning 90° anti-clockwise with a screwdriver.
2. Remove the frame 2 .
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out five times.
➤ Beat the mat 1 or use a vacuum cleaner to remove loose dirt.

If necessary, wash the mat in lukewarm water (about 40 °C) and household detergent then rinse
thoroughly.
Refitting
➤ Replace the frame and close the fixings.

Use a screwdriver to turn the fixings 90° clockwise until they latch.
10.4 Cleaning or Replacing the Control Cabinet Filter Mats

Filter mats protect the control cabinet from ingress of dirt. If the filter mats are clogged, adequate
cooling of the components is no longer ensured. In such a case, clean or replace the filter mats.
Material Warm water and household detergent

Spare parts (as required)
Precondition The power supply disconnecting (isolating) device is switched off,

The machine has cooled down.

60 ASD 9_5712 06 E
10 Maintenance
10.5 Cooler Maintenance
Fig. 22 Control cabinet ventilation grill

1 Ventilation grill
2 Filter mat
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.
10.5 Cooler Maintenance

Regular cleaning of the cooler 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.
Material Brush and vacuum cleaner.

Breathing mask (if required).


9_5712 06 E ASD 61
10 Maintenance
10.6 Heat Recovery System Maintenance
Fig. 23 Cleaning the cooler

1 Cooler
2 Brush
Cleaning the cooler
Do not use sharp objects to clean the cooler. It could be damaged.

Avoid creating clouds of dust.
➤ Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
➤ Heavy and stubborn contamination should be removed by a KAESER Service Technician.
Check the cooler for leaks
➤ Can cooling oil be seen to be leaking?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by KAESER Service.
10.6 Option W1/W2/W3

Heat Recovery System Maintenance
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is dependant
on the characteristics of the heat transfer medium.
➤ Monitor the pressure in the heat transfer medium to detect any pressure drop.
10.6.1 Option W1
External heat recovery
➤ Have the external heat recovery system checked annually by KAESER Service.

62 ASD 9_5712 06 E
10 Maintenance
10.7 Air Filter Maintenance
10.6.2 Option W2/W3

Internal heat recovery
Leakage
Pressure in the cooling oil circuit is generally higher than that in the heat recovery system. If a leak
occurs, oil will run into the heat transfer medium.
1. Check the heat exchanger visually for leaks.
2. Have an authorised KAESER Service Technician check the heat exchanger for internal leaks at
least once a year.
Contamination
➤ Have an authorised KAESER Service Technician clean the heat exchanger as soon as a pressure
drop in the heat transfer medium is detected.
10.7 Air Filter Maintenance

Do not clean the air filter element with liquids.
Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress the pressure system and cause damage to the machine.
Material Replacement part

Fig. 24 Air filter maintenance

1 Nut 4 Air filter element
2 Nut 5 Cover
3 Backplate

9_5712 06 E ASD 63
10 Maintenance
10.8 Motor Maintenance
Opening the air filter housing
1. Undo the nuts 1 fixing the cover 5 to the side panel and take out the complete filter.
2. Unscrew the nut 2 and remove the backplate 3 .
Clean the air filter element by tapping.
➤ Tap the element at the front a number of times with the palm of the hand.
Cleaning the filter element with compressed air
➤ Use dry compressed air at not more than 5 bar to blow dirt from the air filter cartridge from inside
to outside.
Closing the air filter housing
1. Clean all parts and sealing surfaces.

2. Insert the element 4 in the cover 5 and lay on the backplate 3 .
3. Use the screw and nut 2 to hold the housing together.
4. Insert the air filter housing in the side panel and secure by the cover 5 with the nuts 1 .
5. Close all access doors and replace all enclosure panels.
6. Switch on the mains disconnecting device and reset the maintenance interval counter.
10.8 Motor Maintenance

The drive motor bearings are permanently greased. Subsequent greasing is not necessary.
Drive motor
➤ Have the motor bearings checked by the KAESER Service Technician.
Fan motor
➤ Have the motor bearings checked by a KAESER Service Technician.
10.9 Checking the Coupling

A defective coupling is recognisable by:
■ noisy running,
■ surface cracks,
■ colour change.
WARNING
Danger of injury from rotating coupling!
➤ Never switch the machine on without the safety screen in place over the coupling.

64 ASD 9_5712 06 E
10 Maintenance
10.10 Checking the Pressure Relief Valve
Fig. 25 Checking the coupling

1 Safety screen
2 Coupling
Check for uneven or noisy running
Precondition The machine is running
➤ Check the coupling for noisy or uneven running
Make a visual check for damage

1. Remove the securing screws and take off the safety screen.
2. Turn the coupling my hand and look for damage or colour change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Has the coupling cracks or colour changes?
➤ Have a damaged coupling changed by an authorised KAESER Service Technician.
10.10 Checking the Pressure Relief Valve

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blowoff protection and air system pressure monitoring are switched off during the test.
➤ Follow the detailed description of this procedure in the SIGMA CONTROL operating in‐
structions.
➤ Never operate the machine without a fully functioning pressure relief valve.
Precondition The machine is switched off.

Password level 4 is activated.

9_5712 06 E ASD 65
10 Maintenance
10.11 Checking the Excess Temperature Safety Shutdown Function
WARNING
The pressure relief valve blows off.
Excessive noise is caused when the pressure relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air.
➤ Close all access doors; replace and secure all removable panels.
➤ Wear ear and eye protection.
➤ Abort the test if the working pressure rises 10% above the activating pressure of the valve.
1. Close the user's shut-off valve between the machine and the air system.
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. Observe the display of pressure on SIGMA CONTROL and call up the test function.
4. Stop the test as soon as the pressure relief valve blows off or working pressure rises to 10 %
above the activating pressure of the pressure relief valve.
5. If necessary, vent the machine and replace the defective pressure relief valve.
6. Deactivate the test function.
7. Open the user's shut-off valve between the machine and the air system.
10.11 Checking the Excess Temperature Safety Shutdown Function

The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL operating instructions.
The machine does not shut down?.
➤ Have the safety shutdown function checked by an authorized KAESER service represen‐
tative.
10.12 Checking the Cooling Oil Level

The oil level can be seen through a window in the front access door.
Precondition The machine has been running at least 5 minutes under LOAD.

66 ASD 9_5712 06 E
10 Maintenance
10.13 Venting the Machine (depressurizing)
Fig. 26 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum level
➤ Check the oil level with machine running.
Result Top up when the indicator shows minimum level.

The machine must be isolated from the air system and completely vented before undertaking
any work on the pressure system.
The oil circulation vents automatically as soon as the machine is stopped.
Venting takes place in three stages:

■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed 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.

9_5712 06 E ASD 67
10 Maintenance
Fig. 27 Venting the machine

1 Hose coupling (air cooler venting) 7 Shut-off valve
2 Pressure gauge A Shut-off valve open
3 Hose coupling (oil separator tank venting) B Shut-off valve closed
6 Male hose coupling 8 Maintenance hose
Isolate the machine from the air system.
➤ Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.
Venting the oil separator tank
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ 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.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or 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 .

68 ASD 9_5712 06 E
10 Maintenance
10.14 Topping up the Cooling Oil
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

Fig. 28 Topping up the Cooling Oil

1 Hose coupling (air cooler venting) 6 Male hose coupling
2 Pressure gauge 7 Shut-off valve
3 Hose coupling (oil separator tank venting) A Shut-off valve open
4 Oil filler with plug B Shut-off valve closed
5 Cooling oil level indicator 8 Maintenance hose
1. Vent the machine as described in section 10.14.1.

2. Fill with cooling oil and test run as described in section 10.14.2.
10.14.1 Venting the machine (depressurizing)

The oil circulation vents automatically as soon as the machine is stopped.
Venting takes place in three stages:

■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.

9_5712 06 E ASD 69
10 Maintenance
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
Isolate the machine from the air system.
➤ Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.
Venting the oil separator tank
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ 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.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or the section from the shut-off valve to the minimum pressure/
check valve.
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 .
10.14.2 Topping up with cooling oil and trial run

Topping up the cooling oil
A sticker on the oil separator tank specifies the type of oil used.
CAUTION
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.
1. Slowly unscrew the filler plug 4 .

70 ASD 9_5712 06 E
10 Maintenance
10.15 Changing the Cooling Oil
2. Top up to bring the oil to the correct level.

3. Replace the filler plug's sealing ring if necessary and screw the plug into the filler neck.
Starting the machine and carrying out a trial run
1. Close all access doors; replace and secure all removable panels.
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.

The machine must be isolated from the compressed air network and completely vented before
undertaking any work on the pressure system.
Drain the oil completely from the following components:

■ Oil separator tank
■ Oil cooler
■ Airend
■ Internal heat recovery system (option W1/W2/W3)
➤ 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 compressor
itself or from an external source.
An external source of compressed air is necessary in the following cases:

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.
Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.

9_5712 06 E ASD 71
10 Maintenance
Fig. 29 Changing the cooling oil, oil separator tank

1 Hose coupling (air cooler venting) A Shut-off valve open
2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
4 Oil filler port with plug 9 Hose coupling (oil drain)
5 Cooling oil level indicator 10 Shut-off valve (venting line)
6 Male hose fitting 11 Shut-off valve (oil drain)
7 Shut-off valve
Changing the oil with internal pressure Changing the oil using an external compressed
air source.
Machine has been running at least 5 minutes un‐ The power supply disconnecting device is switch‐
der LOAD. ed off.
The machine is fully vented, the pressure gauge The disconnecting device is locked in the off po‐
on the oil separator tank reads 0 bar. sition.
A check has been made that no voltage is
1. Close the shut-off valve 10 in the venting
present.
line.
The machine is fully vented, the pressure gauge
2. Start the machine and watch the oil separator
on the oil separator tank reads 0 bar.
tank pressure gauge 2 until it reads 3–5 bar.
An external source of compressed air is available.
3. Switch off and lock out the power supply dis‐
connecting device and check that no voltage 1. Close the shut-off valve 10 in the venting
is present. line.
4. Wait at least 2 minutes to allow the oil to flow 2. With the shut-off valve closed, insert the male
back to the separator tank. hose fitting 6 into the hose coupling 3 .
3. Connect the maintenance hose to the exter‐
nal air supply.
4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3–5 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
Draining the oil from the separator tank
1. Have an oil receptacle ready.

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

72 ASD 9_5712 06 E
10 Maintenance
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.
Draining the oil from the cooler
Fig. 30 Changing the cooling oil, oil cooler

1 Oil cooler 6 Male hose fitting
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve

4. Open the shut-off valve 3 .
5. Slowly open the shut-off valve 7 and allow cooling oil and air to escape completely until the
pressure gauge reads 0 bar.

9_5712 06 E ASD 73
10 Maintenance
Draining the oil from the airend
Fig. 31 Changing the cooling oil, airend

1 Compressed air outlet on airend 4 Safety screen
2 Hose coupling (oil drainage) 5 Coupling
3 Shut-off valve

4. Open shut-off valves 3 and 7 (Fig. 29)
5. Remove the coupling safety screen 4 and turn the coupling 5 by hand at least five revolutions
until all the oil has run out.
6. Fit the safety screen again.
Result The cooling oil is drained from the airend.

A small amount of cooling oil may flow back into the oil cooler and oil separator tank as a result of
turning the coupling.
Remove this by repeating the steps for draining oil from the separator tank and oil cooler.
Option W1–W3 Draining the oil from the heat recovery system
Shut-off valves are provided for draining the oil from the heat recovery system. In machines equipped
with an external heat recovery system (option W1), the oil is drained from the appropriate point.

74 ASD 9_5712 06 E
10 Maintenance
10.16 Changing the Oil Filter
Fig. 32 Changing the cooling oil, heat recovery system

1 Hose coupling
2 Thermostatic valve
3 Shut-off valve

2. Insert the male hose fitting 6 (Fig. 29) in the hose coupling 2 .
4. Open the shut-off valves 3 and 7 (Fig. 29) and allow the oil to drain completely.
Filling with oil
1. Open the filler plug 4 (Fig. 29) slowly.

2. Fill with cooling oil.
3. Check the filler plug and ring seal for damage and screw the plug back in again.
Starting the machine and carrying out a trial run
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.
➤ Dispose of used oil in accordance with environmental protection regulations.
10.16 Changing the Oil Filter


Cooling oil container

The machine is fully vented, the pressure gauge on the oil separator cartridge reads 0 bar.

9_5712 06 E ASD 75
10 Maintenance
10.17 Changing the Oil Separator Cartridge
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
Fig. 33 Changing the oil filter

1 Oil filter
2 Direction to unscrew
Changing the oil filter
1. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐
ronmental protection regulations.
2. Lightly oil the new filter's O-ring.
3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a test run
4. After about 10 minutes, check the oil level again and top up if necessary.
5. Switch off the machine and visually check for leaks.

The oil separator cartridge cannot be cleaned.

76 ASD 9_5712 06 E
10 Maintenance
The life of the oil separator cartridge is influenced by:

■ contamination in the air drawn into the compressor,
■ adherence to the changing intervals for:
─ cooling oil
─ oil filter
─ air filter

Cleaning rags

The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar.
Fig. 34 Changing the oil separator cartridge

14 Cover 19 Nut (self locking)
15 Dirt trap 20 Fitting
16 Air pipe 21 Gasket
17 Fixing screws 23 Oil separator cartridge
Changing the oil separator cartridge
1. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
2. Unscrew the nut 19 and turn the air pipe 16 to one side.
3. Remove the cover fixing screws 17 and carefully remove the cover 14 .
4. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of according
to environmental protection regulations.
5. Clean all sealing faces.
6. Insert the new oil separator cartridge with gaskets and screw down the cover.
7. Renew the O-ring and strainer in the dirt trap 15 .

9_5712 06 E ASD 77
10 Maintenance
8. Attach the air pipe to the cover 14 with a new, self-locking nut.
9. Replace and tighten all fittings.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a test run
4. Stop the machine after 10 minutes and visually check for leaks.

78 ASD 9_5712 06 E
10 Maintenance
10.18 Document maintenance and service work.
10.18 Document maintenance and service work.

Machine number:
➤ Enter maintenance and service work carried out in the list.
Date Maintenance task carried out Operating hours Signature
Tab. 52 Logged maintenance tasks

9_5712 06 E ASD 79
11.1 Note the Nameplate

11.1 Note the Nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.
11.2 Ordering Consumable Parts and Operating Materials

KAESER consumable parts and operating materials are all genuine KAESER parts. They are selected
for use in KAESER machines.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuitable spare
parts or operating materials.
Unsuitable or poor quality consumable parts and operating materials may damage the machine or
impair its proper function.
In the event of damage, personal injury may result.
➤ Use only genuine KAESER parts and operating materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.
Machine
Name Quantity Number

Air filter element 1 1250
Filter mat (control cabinet) 2 1100
Oil filter 1 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Tab. 53 Consumable parts
11.3 SIGMA AIR SERVICE

SIGMA AIR SERVICE offers:
■ authorised service technicians with KAESER factory training,
■ increased operational reliability ensured by preventive maintenance,
■ energy savings achieved by avoidance of pressure losses,
■ optimum conditions for operation of the compressed air system,
■ the security of genuine KAESER spare parts,
■ increased legal certainty as all regulations are kept to.
➤ Why not sign a SIGMA AIR SERVICE maintenance agreement!
Result Your advantage:

lower costs and higher compressed air availability.

80 ASD 9_5712 06 E
11.4 Service Addresses
11.4 Service Addresses

Addresses of KAESER agents are given at the end of this manual.
11.5 Spare Parts for Service and Repair

With the help of this parts list you can plan your material requirement according to operating conditions
and order the spare parts you need.
➤ Make sure that any service or repair tasks not described in this manual are carried out by
an authorized KAESER Service Technician.

9_5712 06 E ASD 81

82 ASD 9_5712 06 E

9_5712 06 E ASD 83
12.1 Putting Out of Operation

12.1 Putting Out of Operation
This is necessary under the following circumstances:
■ The machine is temporarily not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.
Temporarily putting out of operation
Precondition The machine can be started at regular intervals.
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protection
against corrosion.
Putting out of operation for a longer period
Precondition Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the mains disconnecting device,
check that no voltage is present.
Machine fully vented (no pressure).
1. Allow the machine to cool down completely.

2. Disconnect all air and electrical connections.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Consult an authorized KAESER Service agent for advice on packing for sea or air transport.
Material Desiccant
Plastic sheeting
Wooden transport crate
Precondition The machine is decommissioned.

Machine is dry and cooled down.
1. Place sufficient desiccant (silica gel or similar) inside the machine cabinet.
2. Wrap the machine in plastic sheeting.
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, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and commissioning.

84 ASD 9_5712 06 E
12.4 Transporting
CAUTION
Moisture and frost can damage the machine.
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
➤ Store the machine in a dry, frost-proof room.
12.4 Transporting
12.4.1 Safety
Weight and centre of gravity determine the most suitable method of transport. The centre of gravity
is shown in the drawing in chapter 13.3.
Precondition Transport only by fork truck or lifting gear with personnel trained in the safe transport of goods.
➤ Make sure the danger zone is clear.
12.4.2 Transporting with a forklift truck

Precondition The forks are fully under the machine.
Fig. 35 Transporting with a forklift truck
➤ Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transporting with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fully under the machine.
The slings may not bear on the side of the machine cabinet.
Examples of unsuitable fixing points:

■ Pipe sockets
■ Flanges
■ Attached components such as cyclone separators, condensate drains or filters
■ Rain protection covers
Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the machine cabinet.

9_5712 06 E ASD 85
12.5 Disposal
Fig. 36 Transporting with a crane

1 Lifting gear
2 Slings
CAUTION
The machine can be damaged by incorrect attachment of the lifting gear.
➤ Do not attach the lifting gear to any of the machine components.
➤ The manufacturer can advise on the use of suitable lifting gear.
➤ Use the lifting gear correctly and lift the machine carefully.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove dirty filters.
Precondition The machine is decommissioned.
1. Completely drain the cooling oil from the machine.

2. Remove used filters and the oil separator cartridge.
3. Hand the machine over to an authorized disposal expert.
➤ Components contaminated with cooling oil must be disposed of in accordance with local
environment protection regulations.
Machines with refrigeration dryers
The sealed refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by an authorized body.

86 ASD 9_5712 06 E
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13 Annex

9_5712 06 E ASD 87
13 Annex

88 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 89
13 Annex

90 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 91
13 Annex

92 ASD 9_5712 06 E
13 Annex
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode
13.2 Option C1
Pipe and Instrument Flow Diagram (P+I diagram): MODULATING
control mode

9_5712 06 E ASD 93
13 Annex

94 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 95
13 Annex

96 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 97
13 Annex

98 ASD 9_5712 06 E
13 Annex
13.3 Dimensional Drawing

9_5712 06 E ASD 99
13 Annex

100 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 101
13 Annex
13.4 Electrical Diagram

102 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 103
13 Annex

104 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 105
13 Annex

106 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 107
13 Annex

108 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 109
13 Annex

110 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 111
13 Annex

112 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 113
13 Annex

114 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 115
13 Annex

116 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 117
13 Annex

118 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 119
13 Annex

120 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 121
13 Annex

122 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 123
13 Annex

124 ASD 9_5712 06 E
13 Annex

9_5712 06 E ASD 125
13 Annex

126 ASD 9_5712 06 E

Service Manual: Screw Compressor ASD

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Service Manual

KAESER KOMPRESSOREN GmbH

1 Regarding this document

Service Manual Screw Compressor

4.4 Options ............................................................................................................................. 25

Service Manual Screw Compressor

10.2 Maintenance Schedule ..................................................................................................... 56

Service Manual Screw Compressor

Service Manual Screw Compressor

Fig. 1 Maximum relative humidity ......................................................................................................... 5

Service Manual Screw Compressor

Service Manual Screw Compressor

Tab. 1 The levels of danger and their meaning ..................................................................................... 2

Service Manual Screw Compressor

Service Manual Screw Compressor

1 Regarding this document

1.2 Additional Documents

Missing documents can be requested from KAESER.

1.4 Symbols and Identification

Service Manual Screw Compressor

➤ Always read and comply with warning instructions.

Signal word Meaning Consequences of non-observance

Tab. 1 The levels of danger and their meaning

1.4.2 Other instructions and symbols

Further information Here, your attention is drawn to further topics.

Service Manual Screw Compressor

The nameplate is located on the outside of the machine:

➤ Enter the data from the nameplate here as a reference:

Option Option code Exists?

Service Manual Screw Compressor

ASD 32 ASD 37 ASD 47 ASD 57

Tab. 4 Machine weight

2.5 Ambient Conditions

Tab. 6 Ambient Conditions

Service Manual Screw Compressor

Fig. 1 Maximum relative humidity

ASD 32 ASD 37 ASD 47 ASD 57

Pressure relief valve activating pressure at 50 Hz [bar]

Maximum working pres‐ ASD 32 ASD 37 ASD 47 ASD 57

Tab. 8 Pressure relief valve activating pressure (50 Hz)

Service Manual Screw Compressor

Pressure relief valve activating pressure at 60 Hz [bar]

Maximum working pres‐ ASD 32 ASD 37 ASD 47 ASD 57

Tab. 9 Pressure relief valve activating pressure (60Hz)

Maximum working pres‐ ASD 32 ASD 37 ASD 47 ASD 57

Tab. 10 Delivery (50 Hz)

Delivery [m3/min] at 60 Hz mains frequency

Maximum working pres‐ ASD 32 ASD 37 ASD 47 ASD 57

Tab. 11 Delivery (60 Hz)

2.9 Cooling Oil Recommendation

Service Manual Screw Compressor

Tab. 12 Cooling Oil Recommendation

2.10 Cooling Oil Charge

ASD 32 ASD 37 ASD 47 ASD 57

Tab. 13 Cooling Oil Charge

Option W1/W2/W3 Heat Recovery

Option W1 ASD 32 ASD 37 ASD 47 ASD 57

Tab. 14 Cooling oil charge (option W1)

Service Manual Screw Compressor

ASD 32 ASD 37 ASD 47 ASD 57

Tab. 15 Cooling oil charge (option W2)

Option W3 ASD 32 ASD 37 ASD 47 ASD 57

Tab. 16 Cooling oil charge (option W3)