BSD 40
BSD 40
Screw Compressor
BSD
9_5708 08 USE
Original instructions
/KKW/SBSD 1.02 en 01 SBA-SCHRAUBEN-SC
/KKW/SSC 1.04 01
Contents
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documentation
should be referred to KAESER. Correct use of information will be fully supported.
DANGER
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruction.
➤ The measures required to protect yourself from danger are shown here.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
Option H1 ➤ This bullet is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used in
this service manual are explained in chapter 2.2 .
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protection.
2 Technical Data
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
Characteristic Value
Model
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQUIPMENT NUMBER
Tab. 2 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference.
Tab. 3 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equipment
fitted.
2.4 Temperature
BSD 40 BSD 50 BSD 60
Minimum cut-in tempera‐ 40 40 40
ture [°F]
Typical airend discharge 167–200 167–200 167–200
temperature during opera‐
tion [°F]
Maximum. airend dis‐ 230 230 230
charge temp. (automatic
shut-down) [°F]
Tab. 5 Temperature
2.6 Ventilation
The values given are minimum guide values.
Tab. 7 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
2.8 Delivery
FAD [cfm]
Tab. 9 Delivery
M-SERIES:
■ M-Series SIGMA compressor cooling oils are semi-synthetic lubricants.
■ M-Series SIGMA compressor cooling oils are the highest quality petroleum lubricants. M–460 is
specially blended to provide reliable performance in KAESER screw compressors.
S-SERIES:
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
■ S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐
bricants. These ”synthetic” lubricants begin as high quality petroleum feed stock. They are then
refined, processed and purified into fluids with very consistent molecular structure. These oils are
carefully blended to produce extremely consistant lubricants with superior properties. SIGMA
synthetic lubricants feature all the advantages of both PAO and diester fluids.
■ S–460 lubricant is recommended for compressors operating in ambient temperatures between
40 °F and 105 °F.
Option K1 Air-cooling
Option W1 The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines:
BSD 40 BSD 50 BSD 60
Additional charge vol‐
ume [quart]*
* Enter the volume required by your heat recovery system.
2.11.2 Option K1
Fan motor
BSD 40 BSD 50 BSD 60
Rated power [hp] 1.2 1.2 1.2
h = operating hours
2.11.3 Option K2
Fan motor
BSD 40 BSD 50 BSD 60
Rated power [hp] 0.13 0.13 0.13
Rated speed [rpm] 2700 2700 2700
Enclosure protection TEFC TEFC TEFC
Measurement conditions
■ Free-field measurement to CAGI/PNEUROP PN8 NTC 2.3
■ Measurement distance: 1 m
The machine is designed for an electrical supply according to National Electric Code (NEC) NEC–
670, particularly NFPA 79, edition 2007, section 4.3. In the absence of any user-specified alternatives,
the limits given in these standards must be adhered to. Consult manufacturer for any other specific
power supply.
Further requirements
This machine may only be supplied from a grounded TN or TT three-phase supply in which the neutral
point is grounded.
The machine may not be connected to a three-phase supply in which one of the phases is grounded,
as this can lead to dangerous voltage surges.
Connection to an IT network is not permitted without further measures being taken (ground leak
detection, specially designed frequency converter, etc.).
Further information The wiring diagram in chapter 13.4 contains further details of the power supply connection.
2.15 Option K2
Water-cooling
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connection
ports.
Cooler specification
Characteristics/content Value
pH value 7,5–9
Hardness [°dH] 4,0–8,5
Chloride (Cl) [mg/l] <150
Free chlorine gas (Cl2) [mg/l] <1
Characteristics/content Value
Sulphite (SO3) [mg/l] <1
Dissolved iron (Fe) [mg/l] <0,2
Hydrogen carbonate (HCO3) [mg/l] 70–300
Sulphate (SO4) [mg/l] <70
HCO3/SO4 >1
Electrical conductivity [µS/cm] 10–500
Ammonia (NH3) [mg/l] <2
Dissolved manganese (Mn) [mg/l] <0,1
Dissolved aluminum (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
Characteristics/content Value
pH value 7.5–9
Total 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
Heat capacity
Option W2 Flow rate for heating from 113 °F to 158 °F (equivalent to ΔT = 45F)
DANGER
Disregarding these instructions can result in serious injury.
➤ Read the service manual carefully and take notice of the contents for safe machine operation.
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for which
it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
➤ Ensure that operating, installation and maintenance personnel are qualified and authorized to
carry out their tasks.
3.5 Dangers
Basic Information
Information concerning the various forms of danger that can arise during machine operation are found
here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
Electricity
➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
qualified and authorized electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations .
➤ Before every start-up, the user must make sure there is adequate protection against electric shock
from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Switch off any external power sources.
These could be connections to floating contacts or electrical machine heating, for example.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in order.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or
death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
➤ Vent all pressurized components and chambers completely.
➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized components
(e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Spring tension
Springs under tension or compression represent contained energy. Uncontrolled release of this en‐
ergy can cause serious injury or death.
Minimum pressure/check valves, safety relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result in
serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before starting.
Temperature
Noise
Operating materials
➤ Use only spare parts approved by the manufacturer for use in this machine.
Unsuitable spare parts compromise the safety of the device.
➤ Use only genuine KAESER pressure components.
➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.
Transport
Installation
Further information More information on safety devices is contained in chapter 4, section 4.6.
3.8 Emergencies
3.8.1 Correct fire fighting
Suitable extinguishing agents:
■ Foam
■ Carbon dioxide
■ Sand or dirt
1. Keep calm.
2. Give the alarm.
3. Shut off supply lines if possible.
For example:
■ Power supply disconnecting device (all phases)
Option K2 ■ Cooling water
Option W1–W3 ■ Heat recovery system
4. To ensure safety:
For example:
■ Warn persons in danger
■ help incapacitated persons
■ close the doors
5. Try to extinguish the fire if you have been trained to do so.
3.9 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended under
the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user to
determine its suitability for his specific application.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
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.
4.4 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.
4.4.2 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
4.4.3 Option K2
Water-cooling
Plate heat exchangers in stainless steel are used for water-cooled machines. An additional container
supplements the cooling oil circuit.
This additional container is omitted on machines with heat recovery.
The cooling oil is kept at the ideal temperature for machine operation.
The thermostatic valve opens first so that heat is given up to the heat recovery system. If the heat
recovery system cannot carry away enough heat, the combination valve opens to allow hot oil through
the oil cooler circuit.
Operation:
combination valve opening temperature = thermostatic valve opening temperature
The available heat to be recovered depends on the operating conditions of the machine.
Both oil temperature regulators are equipped with working elements that ensure trouble-free func‐
tioning of the cooling and heat recovery systems.
■ VARIO
Option C1 ■ MODULATING control
The SIGMA CONTROL is factory set to DUAL control mode unless specifically ordered otherwise.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLEto main‐
tain pressure between the preset minimum and maximum values. When maximum pressure is
reached, the machine switches to IDLE. When the preset idling time has elapsed the machine is
STOPPED.
The shorter the idling time 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.
In this control mode, the controller requires two specified times: The running time and the idle /stand‐
still time.
The shorter these time period settings, the sooner (and more frequently) the motor is stopped.
VARIO
The VARIOmode is based on the DUAL control mode. In contrast to DUAL, the idle period is auto‐
matically lengthened or shortened to compensate for higher or lower drive motor starting frequencies.
MODULATING control is based on the DUALcontrol mode. In contrast to DUAL, the air delivery is
continuously varied within the control range of the machine.
This control mode is not available on variable speed machines with a frequency-controlled
drive (SFC).
Fig. 9 Keys
Tab. 38 Keys
Fig. 10 Indicators
Tab. 39 Indicators
Precondition The floor must be level, firm and capable of bearing the weight of the machine.
CAUTION
Ambient temperature too low!
Frozen condensate and highly viscous cooling oil can cause damage when starting the machine.
➤ Make sure that the temperature of the machine is at least +37 F before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
1. If installed outdoors, protect the machine against frost, direct sunlight, dust and rain.
2. Ensure adequate lighting so that all work on the machine can be carried out without danger or
hindrance.
➤ Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
➤ Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually
open.
➤ Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
Further information Further information on installation of exhaust air ducts can be found in chapter 13.3.
6 Installation
6.1 Safety
The following instructions must be followed for safe installation.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
WARNING
Serious injury or death can result from loosening or opening components under pressure.
➤ Vent all pressurized components and chambers completely.
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.
DANGER
Danger of fatal injury from electric shock!
➤ Switch off and lock out the supply disconnecting device and check that no voltage is present.
Further information The electrical diagram 13.4 contains further specifications for electrical connection.
6.5 Options
6.5.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3.
6.5.2 Option K2
Connecting the cooling water
➤ Take the electrochemical series into consideration and choose suitable materials for water
connections.
➤ Keep the effect of pressure surges on the coolers as low as possible.
➤ Install an expansion tank to act as a pulsation damper if pressure surges cannot be avoided.
➤ Avoid a low inlet temperature for the cooling water as it can cause condensation. If required,
contactKAESER for suitable insulation measures.
Temperature-controlled cooling water supply systems, to which numerous machines are connected,
regulate the water flow rate according to the difference in temperature between the supply and the
return water. Individual machines may not receive an adequate flow under this system. Breakdowns
are the result.
➤ KAESER can advise on how to ensure the cooling water supply via suitable control valves.
4. Slowly open the cooling water inlet shut-off valve B to gradually fill the cooler with water.
5. Bleed air from the water lines.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connection
ports.
WARNING
Cooling oil in the heat-receiving medium!
Oil may contaminate the medium if a leak occurs.
➤ Do not use the heat-receiving medium as drinking water.
➤ Install the heat recovery system in accordance with the following specifications.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connection
ports.
6.5.3.1 Option W1
Connecting the external heat recovery system
An unsuitable heat exchanger or incorrect installation may adversely impact the cooling oil cir‐
cuit within the compressor. Damage to the machine will follow.
➤ Consult with KAESER on a suitable heat exchanger and have an authorized KAESER Service
do the installation.
7 Initial Start-up
7.1 Safety
The following instructions must be followed for safe machine commissioning.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
➤ Commissioning of the machine may only be carried out by trained and authorized installation or
maintenance personnel.
Fig. 16 Coupling
1 Compressor block 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
8 Operation
8.1 Switching On and Off
Always switch the machine on with the «ON» key and off with the «OFF» key.
The power supply disconnecting device has been installed by the user.
8.1.1 Switching on
Precondition No one is working on the machine,
all access doors and panels are closed and secure.
Result The compressor motor starts as soon as the network pressure is lower than the setpoint value (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 at 20 seconds:
press the «OFF» key.
The Machine ON LED extinguishes.
The machine is ready for operation. You can switch the machine on again.
3. Switch off and lock out the power supply disconnecting device.
The machine is switched off and isolated from the power supply. The Controller ON LED extin‐
guishes.
Shutdown
Switching on
1. Turn the EMERGENCY STOP pushbutton in the direction of the arrow to unlatch it.
2. Press the reset key to reset any alarm messages.
The machine can now be started again.
1. Attach an easily seen notice to the machine that warns of remote operation.
or
Alarm message
An alarm shuts the machine down automatically. The red LED alarm flashes.
The last line in the display shows the actual fault causing the alarm.
Further information A list of possible alarm messages occurring during operation are shown in chapter 9.2.
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the yel‐
low warning LED flashes.
The last line in the display shows the warning message.
Further information A list of possible warning messages occurring during operation are shown in chapter 9.3.
The messages valid for your machine are dependant on the controller and individual equipment.
1. Do not attempt fault removal measures other than those given in this manual.
2. In all other cases:
have the fault rectified by an authorized KAESER Service representative agent.
bus alarm The bus link from the Profibus DP Check bus highway and plug.
interface is interrupted.
PD T↑ Compressed air discharge temper‐ Clean the cooler.
ature too high. Check the cooling oil level.
PD T↓ Package discharge (PD) tempera‐ Call KAESER Service.
ture too low.
DO test The 'controller outputs' test function Stop the 'controller output' mode.
is activated.
restart inhibit Too frequent manual on and off Do not exceed the maximum number of mo‐
switching. tor switchings per hour when manual on/off
switching.
elect. equip. h⇞ The maintenance interval for check‐ Carry out the check and reset the mainte‐
ing electrical equipment and wiring nance interval counter.
has expired.
error: FEPROM Internal controller memory error. Call KAESER Service.
error: RAM Internal RAM defective. Call KAESER Service.
10 Maintenance
10.1 Safety
The following instructions must be followed for safe machine maintenance.
Warning instructions are always given before a potentially dangerous action.
1. Work on electrically conducting components may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting device and check that no voltage is present.
3. Check that there is no voltage on floating relay contacts.
1. Close shut-off valves or otherwise isolate the machine from the air main to ensure that no com‐
pressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all machine hose connectors with a handheld pressure gauge to ensure that all read zero.
4. Do not open or dismantle such valves.
1. Switch off and lock out the supply disconnecting device and check that no voltage is present.
2. Do not open the enclosure while the machine is switched on.
➤ Adjust the maintenance intervals with regard to local installation and operating conditions.
➤ Keep a log of all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recommen‐
dations to be determined.
1. Select the appropriate entry from the < maintenance > menu.
2. Set < reset: > to y and confirm with «Apply».
Further information Detailed information can be found in the SIGMA CONTROL operating instructions.
➤ Please observe national regulations regarding the use of cooling oil in oil-injected screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary.
KAESER LUBRICANTS
SIGMA Lubricant Description Maximum Recommended Change Interval
First oil change Subsequent oil change
M–460 ISO 46 Semi-Synthetic 2,000 Hours 3,000 Hours
Lubricant
S–460 ISO 46 Synthetic Lubri‐ 6,000 Hours 8,000 Hours
cant
S–680 ISO 68 Synthetic Lubri‐ 6,000 Hours 8,000 Hours
cant
KAESER LUBRICANTS
SIGMA Lubricant Description Maximum Recommended Change Interval
First oil change Subsequent oil change
FG–460 ISO 46 Food Grade 2,000 Hours 3,000 Hours
Synthetic Fluid
10.3 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat helps to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer ensured.
Removal
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out 5 times.
Refitting
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 Option K1
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.
10.6 Option K2
Water-cooling Maintenance
Cooler clogging causes overheating and machine damage.
➤ Observe the airend discharge temperature to detect any tendency to rise.
Check the cooler regularly for leaks and contamination. Frequency of checking is dependant on the
characteristics of the cooling water.
Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak
occurs, oil will run into the cooling water.
Cleaning
➤ An authorized KAESER Service representative should clean the cooler when the airend dis‐
charge temperature is 10 K above the annual average.
10.7.1 Option W1
External heat recovery system
➤ Have the external heat recovery system checked annually by KAESER Service.
1. Unscrew the nuts 4 and lift out the cover 3 together with the air filter element 2 .
2. Unscrew the nut 1 and remove the filter element.
Renew the filter element at the latest after it has been cleaned 5 times.
➤ Tap the element at the front a number of times with the palm of the hand.
➤ Use dry compressed air at less than 70 psig to blow dirt from the air filter element from inside to
outside.
WARNING
Danger of burns from hot components.
➤ Wear long-sleeved clothing and gloves.
➤ Work with caution.
Drive motor
➤ Have the fan motor bearings checked by a KAESER Service representative during the course of
a visit.
■ surface cracks,
■ color change.
WARNING
Danger of injury from rotating coupling!
➤ Never switch the machine on without the safety screen in place over the coupling.
1. Remove the securing screws and take off the safety screen.
2. Turn the coupling by hand and look for damage or color change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Does the coupling have cracks or color changes?
➤ Have a damaged coupling changed by an authorized KAESER Service representative.
Blowoff protection and network pressure monitoring are switched off during the test.
➤ Follow the detailed procedure instructions in the SIGMA CONTROL manual.
➤ Operate the machine only with a fully functioning safety relief valve.
WARNING
Safety relief valve blows off.
Excessive noise is caused when the safety relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air.
➤ Close all access doors; replace and secure all removable panels.
➤ Wear ear and eye protection.
➤ Abort the test if the working pressure reaches 10% above the blowoff pressure of the valve.
1. Close the user's shut-off valve between the machine and the compressed air system.
2. Read the blowoff pressure on the valve.
(the blowoff pressure is usually to be found at the end of the part identification)
3. Observe the pressure indicator on the SIGMA CONTROL and call up the test function.
4. Stop the test as soon as the safety relief valve blows off or working pressure reaches 10 % above
the blowoff set point.
5. If necessary, vent the machine and replace the safety relief valve.
6. Deactivate the test function.
7. Open the user's shut-off valve between the machine and the compressed air system.
Precondition The machine has been running at least 5 minutes under LOAD.
WARNING
Danger of burning from hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.
Material The hose coupling, shut-off valve and maintenance hose lie beneath the oil separator tank.
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.
➤ Close the user's shut-off valve between the machine and the compressed air system.
If no shut-off valve is provided, the complete compressed air system must be vented.
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at a person while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 psig.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the compressed air system is vented to
atmospheric.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Withdraw the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an
authorized KAESER Service representative.
After shutting down the compressor and venting the oil separator tank, there is still pressure on
the machine from the compressed air system or in the section from the shut-off valve to the
minimum pressure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
Material The hose coupling, shut-off valve and maintenance hose lie beneath the oil separator tank.
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.
➤ Close the user's shut-off valve between the machine and the compressed air system.
If no shut-off valve is provided, the complete compressed air system must be vented.
WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at a person while venting.
➤ Do not inhale the oil mist.
➤ Check that the oil separator tank pressure gauge reads 0 psig.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the compressed air system is vented to
atmosphere.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Withdraw the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an
authorized KAESER Service representative.
After shutting down the compressor and venting the oil separator tank, there is still pressure on
the machine from the compressed air system or in the section from the shut-off valve to the
minimum pressure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Withdraw the male hose fitting 6 and close the shut-off valve 7 .
A sticker on the oil separator tank gives the type of oil it contains.
CAUTION
The machine could be damaged by unsuitable oil
➤ Never mix different types of oil.
➤ Top up only with the same type of oil as already in the machine.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air system.
3. After about 10 minutes, check the oil level again and top up if necessary.
4. Switch off the machine and visually check for leaks.
➤ 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.
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
Changing the oil with internal pressure Changing the oil using an external compressed
air source
Machine has been running at least 5 minutes un‐ The power supply isolating device is switched off,
der LOAD. the device is locked off,
The machine is fully vented, the pressure gauge a check has been made that no voltage is present.
on the oil separator tank reads 0 bar. The machine is fully vented, the pressure gauge
1. Close the shut-off valve 10 in the venting on the oil separator tank reads 0 psig.
line. An external source of compressed air is available.
2. Select IDLE running. 1. Close the shut-off valve 10 in the venting
3. Start the machine and watch the oil separator line.
tank pressure gauge 2 until it reads 43–73 2. With the shut-off valve closed, insert the male
psig. hose fitting 6 into the hose coupling 3 .
4. Switch off and lock out the power supply dis‐ 3. Connect the maintenance hose to the exter‐
connecting device and check that no voltage nal air supply.
is present. 4. Open the shut-off valve 7 until the pressure
5. Wait at least 2 minutes to allow the oil to flow gauge on the oil separator tank reads 43–
back to the separator tank. 73 psig.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Option W1 Draining the oil from the external heat recovery system
If the machine is connected to an external heat recovery system, drain the oil from the heat exchanger
at a suitable point.
Option W2/W3 Draining cooling oil from the internal heat exchanger
A shut-off valve is provided for draining the oil from the heat exchanger.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air distribution network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
5. Switch off the machine and check visually for leaks.
➤ Dispose of used oil in accordance with environment protection regulations.
WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.
1. Unscrew the oil filter counter-clockwise, catch oil spillage and dispose of in accordance with
environmental 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.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air system.
3. Switch on the power supply and reset the maintenance interval counter.
4. After about 10 minutes, check the oil level again and top up if necessary.
5. Switch off the machine and visually check for leaks.
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 retaining screws 17 and carefully lift the cover 14 .
4. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of these
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. Install a new O-ring and strainer in the dirt trap 15 .
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.
1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air system.
3. Switch on the power supply and reset the maintenance interval counter.
4. Stop the machine after 10 minutes and visually check for leaks.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuitable spares
or operating fluids/materials.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from machine damage.
➤ Use only original KAESER parts and operating fluids/materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.
Machine
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protection
against corrosion.
Precondition Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the power supply disconnecting device,
the disconnect device is locked in the off position,
check that no voltage is present.
Machine fully vented (no pressure).
12.2 Packing
A wooden crate is required for ground transport to protect the machine from mechanical damage.
Consult an authorized KAESER Service representative for advice on packing for sea or air transport.
Material Desiccant
Plastic sheeting
Wooden transport crate
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and oil separator tank.
Frozen moisture can damage components, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and re-commissioning.
CAUTION
Machine damage from moisture and frost.
➤ Prevent ingress of moisture and condensation.
➤ Maintain >32 °F storage temperature.
12.4 Transporting
12.4.1 Safety
Weight and center of gravity determine the suitable transporting method. The center of gravity is
shown in the drawing in chapter 13.3.
Precondition Transport only by fork truck or lifting cradle and with personnel trained in the safe use of the transport
equipment.
➤ Drive the forks completely under the machine or palette and lift carefully.
CAUTION
Machine damage by incorrect lifting cradle attachment.
➤ Do not attach the lifting cradle to any of the machine components.
➤ The machine manufacturer can advise on application of a suitable lifting cradle.
➤ Use the lifting cradle correctly and lift the machine carefully.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove dirty filters.
The sealed refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by authorized personnel.
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13.2 Option C1
Pipe and Instrument Flow Diagram (P+I diagram): MODULATING
control mode