BSD 40

Service Manual
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 Regarding this Document

1.1 Using the Document ......................................................................................................... 1
1.2 Further 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 Data
2.1 Nameplate ........................................................................................................................ 3
2.2 Options ............................................................................................................................. 3
2.3 Weight .............................................................................................................................. 4
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
2.9.1 Basic Information ................................................................................................ 6
2.9.2 KAESER Lubricants ............................................................................................ 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
2.11.3 Fan motor ........................................................................................................... 9
2.12 Sound Pressure Level ...................................................................................................... 9
2.13 Power Supply ................................................................................................................... 9
2.14 Power Supply Specifications ............................................................................................ 10
2.15 Water-cooling ................................................................................................................... 11
2.15.1 Design data ......................................................................................................... 11
2.15.2 Cooling water quality .......................................................................................... 12
2.16 Heat recovery ................................................................................................................... 13
2.16.1 Prepared for external heat recovery ................................................................... 13
2.16.2 Internal heat recovery ......................................................................................... 13
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 16
3.2 Specified use .................................................................................................................... 16
3.3 Improper Use ................................................................................................................... 16
3.4 User's Responsibilities ..................................................................................................... 16
3.4.1 Observe statutory and universally accepted regulations .................................... 16
3.4.2 Qualified personnel ............................................................................................. 17
3.4.3 Adhere to Inspection Schedules and Accident Prevention Regulations. ............ 17
3.5 Dangers ............................................................................................................................ 17
3.5.1 Safely Dealing with Sources of Danger .............................................................. 18
3.5.2 Safe Machine Operation ..................................................................................... 20
3.5.3 Organizational Measures .................................................................................... 20
3.5.4 Danger Areas ...................................................................................................... 20
3.6 Safety Devices ................................................................................................................. 21
3.7 Safety Signs ..................................................................................................................... 21
3.8 Emergencies .................................................................................................................... 23
3.8.1 Correct fire fighting ............................................................................................. 23
3.8.2 Remove any cooling oil from your person .......................................................... 24
3.9 Warranty ........................................................................................................................... 24
3.10 Environmental Protection ................................................................................................. 24
Service Manual Screw Compressor

9_5708 08 USE BSD i
Contents
4 Design and Function

4.1 Enclosure ......................................................................................................................... 25
4.2 Functional Description of the Machine ............................................................................. 25
4.3 Floating relay contacts ..................................................................................................... 26
4.4 Options ............................................................................................................................. 27
4.4.1 Machine mountings ............................................................................................. 27
4.4.2 Cooling air filter mat ............................................................................................ 27
4.4.3 Water-cooling ...................................................................................................... 27
4.4.4 Heat recovery ..................................................................................................... 28
4.5 Operating modes and control modes ............................................................................... 29
4.5.1 Operating modes ................................................................................................ 29
4.5.2 Control modes .................................................................................................... 29
4.6 Safety Devices ................................................................................................................. 31
4.7 SIGMA CONTROL Keys and Indicators .......................................................................... 31
5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 34
5.2 Installation conditions ....................................................................................................... 34
5.2.1 Determining location and clearances .................................................................. 34
5.2.2 Ensure adequate ventilation. .............................................................................. 35
5.2.3 Exhaust duct design ........................................................................................... 35
5.3 Using the Compressor to Supply A Compressed Air System. ......................................... 36
6 Installation
6.1 Safety ............................................................................................................................... 37
6.2 Reporting Transport Damage ........................................................................................... 37
6.3 Making the Compressed Air Connection .......................................................................... 37
6.4 Making the Power Supply Connection ............................................................................. 38
6.5 Options ............................................................................................................................. 39
6.5.1 Anchoring the machine ....................................................................................... 39
6.5.2 Connecting the cooling water ............................................................................. 39
6.5.3 Connecting the heat recovery system ................................................................ 40
7 Initial Start-up
7.1 Safety ............................................................................................................................... 42
7.2 To be noted before commissioning .................................................................................. 42
7.3 Checking installation and operating conditions ................................................................ 43
7.4 Setting the overload protection cut-out ............................................................................ 44
7.5 Setting the motor overload protection switch ................................................................... 44
7.6 Filling cooling oil into the airend ....................................................................................... 44
7.7 Checking direction of rotation ........................................................................................... 45
7.8 Starting the machine for the first time .............................................................................. 46
7.9 Setting the Setpoint Pressure .......................................................................................... 46
7.10 Changing the display language ........................................................................................ 46
8 Operation
8.1 Switching On and Off ....................................................................................................... 48
8.1.1 Switching on ....................................................................................................... 48
8.1.2 Shutdown ............................................................................................................ 48
8.2 Switching Off in an Emergency and Switching On again ................................................. 49
8.3 Switching on and off from a remote control center ........................................................... 49
8.4 Switching on and off with the clock .................................................................................. 50
8.5 Acknowledging alarm and warning messages ................................................................. 51
9 Fault Recognition and Rectification
9.1 Basic Information ............................................................................................................. 53
9.2 Alarm messages (machine stop) ...................................................................................... 53

ii BSD 9_5708 08 USE
Contents
9.3 Warning messages (yellow LED lights) ............................................................................ 56

9.4 Other Faults ..................................................................................................................... 60
10 Maintenance
10.1 Safety ............................................................................................................................... 62
10.2 Maintenance schedule ..................................................................................................... 63
10.2.1 Logging maintenance work ................................................................................. 63
10.2.2 Resetting maintenance interval counters ............................................................ 63
10.2.3 Regular maintenance tasks ................................................................................ 63
10.2.4 Cooling oil changing interval ............................................................................... 64
10.2.5 Regular service tasks ......................................................................................... 65
10.3 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 65
10.4 Cleaning or Replacing the Control Cabinet Filter Mats .................................................... 66
10.5 Cooler Maintenance ......................................................................................................... 67
10.6 Water-cooling Maintenance ............................................................................................. 68
10.7 Maintain the heat recovery system .................................................................................. 69
10.7.1 External heat recovery system ........................................................................... 69
10.7.2 Internal heat recovery ......................................................................................... 69
10.8 Air Filter Maintenance ...................................................................................................... 69
10.9 Motor Maintenance .......................................................................................................... 70
10.10 Checking the Coupling ..................................................................................................... 71
10.11 Checking the Safety Relief Valve ..................................................................................... 72
10.12 Checking the Overheating Safety Shutdown Function ..................................................... 73
10.13 Checking the Cooling Oil Level ........................................................................................ 73
10.14 Venting the machine (depressurizing) .............................................................................. 74
10.15 Topping up the Cooling Oil ............................................................................................... 76
10.15.1 Venting the Machine (depressurizing) ................................................................ 76
10.15.2 Top up with cooling oil and test run .................................................................... 77
10.16 Changing the cooling oil ................................................................................................... 78
10.17 Changing the Oil Filter ..................................................................................................... 83
10.18 Changing the Oil Separator Cartridge .............................................................................. 84
10.19 Document maintenance and service work. ...................................................................... 87
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 88
11.2 Ordering consumable parts and operating fluids/materials .............................................. 88
11.3 KAESER AIR SERVICE .................................................................................................. 88
11.4 Service Addresses ........................................................................................................... 89
11.5 Spare Parts for Service and Repair ................................................................................. 89
12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation .................................................................................................. 94
12.2 Packing ............................................................................................................................ 94
12.3 Storage ............................................................................................................................. 94
12.4 Transporting ..................................................................................................................... 95
12.4.1 Safety .................................................................................................................. 95
12.4.2 Transporting with a forklift ................................................................................... 95
12.4.3 Transporting with a crane ................................................................................... 95
12.5 Disposal ........................................................................................................................... 96
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 97
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 103
13.3 Dimensional Drawing ....................................................................................................... 109
13.4 Electrical Diagram ............................................................................................................ 113

9_5708 08 USE BSD iii
Contents

iv BSD 9_5708 08 USE
List of Illustrations
Fig. 1 Maximum relative humidity ......................................................................................................... 5

Fig. 2 Location of safety signs .............................................................................................................. 22
Fig. 3 Enclosure overview .................................................................................................................... 25
Fig. 4 Machine layout ........................................................................................................................... 26
Fig. 5 Machine mountings .................................................................................................................... 27
Fig. 6 Cooling air filter mat (option K3) ................................................................................................. 27
Fig. 7 Water-cooling (option K2) ........................................................................................................... 28
Fig. 8 Internal heat recovery (option W2/W3) ....................................................................................... 29
Fig. 9 Keys ........................................................................................................................................... 31
Fig. 10 Indicators .................................................................................................................................... 32
Fig. 11 Recommended machine placement and dimensions [mm] ........................................................ 35
Fig. 12 Compressed air connection ........................................................................................................ 38
Fig. 13 Connecting the cooling water ..................................................................................................... 39
Fig. 14 Connecting the heat recovery system ........................................................................................ 41
Fig. 15 Inlet valve filling port ................................................................................................................... 45
Fig. 16 Coupling ..................................................................................................................................... 45
Fig. 17 Label: Changing the display language ....................................................................................... 47
Fig. 18 Switching on and off ................................................................................................................... 48
Fig. 19 Switching off in an emergency ................................................................................................... 49
Fig. 20 Switching on and off from a remote control center ..................................................................... 50
Fig. 21 Switching on and off with the clock ............................................................................................ 51
Fig. 22 Acknowledging messages .......................................................................................................... 52
Fig. 23 Cooling air filter mat ................................................................................................................... 66
Fig. 24 Control cabinet ventilation grill ................................................................................................... 67
Fig. 25 Cleaning the cooler .................................................................................................................... 68
Fig. 26 Air filter maintenance .................................................................................................................. 70
Fig. 27 Drive motor maintenance ........................................................................................................... 71
Fig. 28 Checking the coupling ................................................................................................................ 72
Fig. 29 Checking the cooling oil level ..................................................................................................... 74
Fig. 30 Venting the machine ................................................................................................................... 75
Fig. 31 Topping up the Cooling Oil ......................................................................................................... 76
Fig. 32 Changing the cooling oil, oil separator tank ............................................................................... 79
Fig. 33 Changing the cooling oil, oil cooler ............................................................................................. 80
Fig. 34 Changing the cooling oil, airend ................................................................................................. 81
Fig. 35 Changing the cooling oil, oil tank ................................................................................................ 82
Fig. 36 Changing the cooling oil, heat recovery system ......................................................................... 83
Fig. 37 Changing the oil filter .................................................................................................................. 84
Fig. 38 Changing the Oil Separator Cartridge ........................................................................................ 85
Fig. 39 Transporting with a forklift .......................................................................................................... 95
Fig. 40 Transporting with a crane ........................................................................................................... 96

9_5708 08 USE BSD v
List of Illustrations

vi BSD 9_5708 08 USE
List of Tables
Tab. 1 The levels of danger and their meaning ..................................................................................... 1

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 Safety relief valve setting .......................................................................................................... 5
Tab. 9 Delivery ..................................................................................................................................... 6
Tab. 10 Cooling oil charge (Option K1) ................................................................................................... 7
Tab. 11 Cooling oil charge (Option K2) ................................................................................................... 7
Tab. 12 Cooling oil charge (Option W1) .................................................................................................. 8
Tab. 15 Drive motor ................................................................................................................................. 8
Tab. 16 Fan motor (option K1) ................................................................................................................ 8
Tab. 17 Fan motor (option K2) ................................................................................................................ 9
Tab. 18 Sound pressure level .................................................................................................................. 9
Tab. 19 Supply 208V/3/60Hz ................................................................................................................... 10
Tab. 20 Connection details 230V/3/60Hz ................................................................................................ 10
Tab. 23 Supply 575V/3/60Hz ................................................................................................................... 11
Tab. 24 Cooling water temperature (ΔT=20°F) ....................................................................................... 11
Tab. 25 Cooling water temperature (ΔT=50°F) ....................................................................................... 12
Tab. 26 Cooler specification (option K2) ................................................................................................. 12
Tab. 27 Cooling water quality .................................................................................................................. 12
Tab. 28 Heat capacity (option W1) .......................................................................................................... 13
Tab. 29 Water quality specification .......................................................................................................... 14
Tab. 30 Heat exchanger specification (option W2/W3) ........................................................................... 14
Tab. 31 Heat capacity (option W2/W3) .................................................................................................... 15
Tab. 32 Flow rate / pressure loss (option W2) ......................................................................................... 15
Tab. 33 Flow rate / pressure loss (option W3) ......................................................................................... 15
Tab. 34 Danger Areas ............................................................................................................................. 21
Tab. 35 Safety Signs ............................................................................................................................... 22
Tab. 36 Energy-efficient control modes ................................................................................................... 30
Tab. 37 Operating modes under MODULATING control ......................................................................... 30
Tab. 38 Keys ........................................................................................................................................... 31
Tab. 39 Indicators .................................................................................................................................... 32
Tab. 40 Re-commissioning after storage ................................................................................................. 43
Tab. 41 Installation and operating conditions checklist ........................................................................... 43
Tab. 42 Machine identification ................................................................................................................. 50
Tab. 43 Remote control identification ...................................................................................................... 50
Tab. 44 Machine identification ................................................................................................................. 51
Tab. 45 Alarm messages and measures ................................................................................................. 53
Tab. 46 Warning messages ..................................................................................................................... 56
Tab. 47 Other faults and actions ............................................................................................................. 60
Tab. 48 Regular maintenance tasks ........................................................................................................ 63
Tab. 49 Oil change intervals lubricants ................................................................................................... 64
Tab. 50 Regular service tasks ................................................................................................................. 65
Tab. 51 Logged maintenance tasks ........................................................................................................ 87
Tab. 52 Consumable parts ...................................................................................................................... 88

9_5708 08 USE BSD vii
List of Tables

viii BSD 9_5708 08 USE
1.1 Using the Document

1.1 Using the Document
The service manual is part of the machine.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on 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 Further 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,
■ operating instructions (for SIGMA CONTROL).
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.
➤ 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

9_5708 08 USE BSD 1
1.4 Symbols and Identification
Signal word Meaning Consequences of non-observance

WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible
tion
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 BSD 9_5708 08 USE
2 Technical Data
2.1 Nameplate
2 Technical Data
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 data from the nameplate here as reference:
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.
Option Option code Available?

Modulating control C1
SIGMA CONTROL C3
Adjustable machine mountings H1
Air-cooling K1
Water cooling K2
Cooling-air filter mat K3
Transformer power supply for refrigeration dryer T2
Prepared for heat recovery W1

9_5708 08 USE BSD 3
2 Technical Data
2.3 Weight
Option Option code Available?

Heat recovery ΔT=45 K W2
Heat recovery ΔT=55 K W3
Tab. 3 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equipment
fitted.
BSD 40 BSD 50 BSD 60

Weight [lb] 2270 2350 2540
Tab. 4 Machine weight
2.4 Temperature
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
2.5 Ambient Conditions

Maximum elevation [ft.] 3000 3000 3000
Permissible ambient tem‐ 40–115 40–115 40–115
perature [°F]
Cooling air temperature 40–115 40–115 40–115
[°F]
Inlet air temperature [°F] 40–115 40–115 40–115
Maximum relative humidi‐ see figure 1 see figure 1 see figure 1
ty of inlet air
* Higher elevation permissible only after consultation with the manufacturer
Tab. 6 Ambient Conditions

4 BSD 9_5708 08 USE
2 Technical Data
2.6 Ventilation
Fig. 1 Maximum relative humidity

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

Inlet aperture Z see fig‐ 8.6/2.2* 10.8/2.2* 12.9/2.2*
ure 11 [sq.ft.]
Forced ventilation with ex‐ 6474 7946 9712
haust fan: 942* 1177* 1471*
Flow rate [cfm] at 0.4 in wc
Exhaust duct: 27 1/2 x 27 1/2 27 1/2 x 27 1/2 27 1/2 x 27 1/2
Dimensions [in]
* Option K2
Tab. 7 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate
Safety relief valve blow-off setting [psig]:
Maximum working pres‐ BSD 40 BSD 50 BSD 60

sure [psig]
125 155 155 155
175 230 230 230
217 — 232 232
Tab. 8 Safety relief valve setting

9_5708 08 USE BSD 5
2 Technical Data
2.8 Delivery
2.8 Delivery
FAD [cfm]
Maximum working pres‐ BSD 40 BSD 50 BSD 60

sure [psig]
125 193 236 288
175 157 190 230
217 — 154 185
Tab. 9 Delivery
2.9 Cooling Oil Recommendation

A sticker showing the type of oil filled is located near the oil separator filler.
Information for ordering cooling oil can be found in chapter 13.4.
2.9.1 Basic Information

Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in
compressor cooling oils. These deposits block the flow of lubricant and cause excessive wear and
failure of moving parts. Contamination of the lubricant can allow the formation of acids, causing ex‐
tensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors do much more than lubricate. During the compression process, it
acts as a sealant in the airend which is important for maximum efficiency. The lubricant also absorbs
much of the heat of compression to cool the airend and reduce the temperature of the compressed
air. It’s not enough that a compressor cooling oil lubricates well, it must stand up to the heat, pressure
and contaminants that are present in every air compressor.
2.9.2 KAESER Lubricants

KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do
not re-use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐
pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire-
resistant fluid. It has a flash point above 460 °F. Since the user has total control over the conditions
of the compressor lubricant, he assumes total responsibility for its safe usage.
Material Safety Data Sheets are available for each lubricant from your authorized KAESER Service
representative.
Regardless of the lubricant selected, the KAESER SIGMA lubricants will separate readily from water.
If condensate occurs it can easily be removed. Let the compressor sit so that any water can drain
back to the separator tank and separate to the bottom. See chapter 10.16 proper draining procedure.
KAESER has several lubricants available that are specially formulated to match these demands. They
feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long life.
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.

6 BSD 9_5708 08 USE
2 Technical Data
2.10 Cooling oil charge
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.
Specialty KAESER LUBRICANTS:

■ S–680 lubricant may be used when ambient temperatures are always between 70 °F and 105 °F.
■ FG–460 synthetic hydrocarbon based food grade lubricant is designed for use in rotary screw
compressors in the application where incidental food contact may occur with the discharge air.
This lubricant meets the requirements of the FDA Regulation 21 CFR §178.3570 and is USDA H–
1 approved and NSF certified. FG–460 is approved for canning, food packing, meat and poultry
processing and other applications where incidental food contact may occur.
2.10 Cooling oil charge

The required cooling oil charge depends on the optional heat recovery system. For machines with
options W1, W2, or W3, the volume required additionally for the heat recovery must be added to the
charge.
Option K1 Air-cooling

Fluid volume* [gal] 6.9 6.9 6.9
Topping up volume [quart] 4.4 4.4 4.4
(minimum–maximum)
* Plus the oil volume of the heat recovery system.
Tab. 10 Cooling oil charge (Option K1)
Option K2 Water cooling

Fluid volume [gal] 8.2 8.2 8.2
Fluid quantity* [gal] 5.3 5.3 5.3
for options W1, W2, or W3
Topping up volume [quart] 4.4 4.4 4.4
(minimum–maximum)
* Plus the oil volume of the heat recovery system.
Tab. 11 Cooling oil charge (Option K2)

9_5708 08 USE BSD 7
2 Technical Data
2.11 Motors and Power
Option W1/W2/W3 Heat recovery
Option W1 The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines:
Additional charge vol‐
ume [quart]*
* Enter the volume required by your heat recovery system.
Tab. 12 Cooling oil charge (Option W1)
Option W2 BSD 40 BSD 50 BSD 60

Additional charge vol‐ 4.4 4.4 4.4
ume [quart]
Option W3 BSD 40 BSD 50 BSD 60

Additional charge vol‐ 1.6 1.6 1.6
ume [quart]
2.11 Motors and Power

2.11.1 Drive motor
Rated power [hp] 40 50 60
Rated speed [rpm] 3565 3565 3570
Enclosure protection TEFC TEFC TEFC
Motor bearing greasing in‐ 2000 2000 2000
terval [h]
Grease requirement, each
bearing [g]**
** Transfer data from the motor nameplate to the table for reference purposes.
h = operating hours
Tab. 15 Drive motor
2.11.2 Option K1
Fan motor
Rated power [hp] 1.2 1.2 1.2
h = operating hours

8 BSD 9_5708 08 USE
2 Technical Data
2.12 Sound Pressure Level

h = operating hours
Tab. 16 Fan motor (option K1)
2.11.3 Option K2
Fan motor
Rated power [hp] 0.13 0.13 0.13
Tab. 17 Fan motor (option K2)
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 lev‐ 68 69 71
el [dB (A)]
Tab. 18 Sound pressure level
2.13 Power Supply

Basic requirements
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
Demands on a three-phase supply for a machine with the following equipment:

■ Refrigeration dryer powered from a transformer

9_5708 08 USE BSD 9
2 Technical Data
2.14 Power Supply Specifications
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.
2.14 Power Supply Specifications

The following multi-strand copper core wires are given according to 2008 NEC 310.15, Table 310.16
for 40 °C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should be
checked and adjusted according to 2008 NEC 110.14©, 220.3,310.15, Table 310.16, 430.6, 430.22,
430.24 and other local codes.
Dual element time delay fuses are selected according to 2008 NEC 240.6,430.52and tables 430.52,
430.248 and 430.250.
We strongly suggest using a separate copper conductor for the equipment GROUNDING. NEC Ta‐
ble 250.122 will point out the ”minimum size”, however, we recommend a ground conductor the same
size as the power leads, if local codes allow.
Rated power supply 208V ±10%, 3-ph, 60Hz

Pre-fuse [A] 175/150* 200 —
Supply 4x AWG2/0** 4x AWG4/0** —
Consumption [A] 121 146 —
** 75 °C
Tab. 19 Supply 208V/3/60Hz
Rated power supply 230V±10%/3/60Hz

Pre-fuse [A] 150 175 —
Supply 4x AWG2/0**/ 4x AWG3/0** —
AWG1/0** *
Consumption [A] 108/105* 131/128* —/—*
* Option K2
** 75 °C
Tab. 20 Connection details 230V/3/60Hz

10 BSD 9_5708 08 USE
2 Technical Data
2.15 Water-cooling

Pre-fuse [A] 90 110 150/125*
Supply 4x AWG1 4x AWG1**/ 4x AWG1/0**
AWG1/0** *
Consumption [A] 66/64* 81/79* 100/98*
* Option K2
** 75 °C

Pre-fuse [A] 80 100/90* 110
Supply 4x AWG2/AWG3* 4x AWG1 4x AWG1**
Consumption [A] 56/54* 67/66* 82/81*
* Option K2
** 75 °C
Rated power supply 575V ±10%, 3-ph, 60Hz

Pre-fuse [A] 60 80/70* 90
Supply 4x AWG4 4x AWG3 4x AWG1
Consumption [A] 43 54 66
** 75 °C
Tab. 23 Supply 575V/3/60Hz
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.
2.15.1 Design data

Cooling water temperature rise 20 °F

Max. permissible inlet 104 104 104
temperature [ °F]
Water flow rate [gpm] 3 3 5

9_5708 08 USE BSD 11
2 Technical Data
2.15 Water-cooling

Pressure drop [psi] 3 3 4
Tab. 24 Cooling water temperature (ΔT=20°F)
Cooling water temperature rise 50 °F

Max. permissible inlet 68 68 68
temperature [ °F]
Water flow rate [gpm] 7 8 13
Pressure drop [psi] 5 6 11
Tab. 25 Cooling water temperature (ΔT=50°F)
Cooler specification

Material 1.4401 1.4401 1.4401
Braze Copper (Cu) Copper (Cu) Copper (Cu)
Maximum working pres‐ 145 145 145
sure [psig]
(cooling water)
Max. permissible dis‐ 158 158 158
charge temp. [ °F]
Unsuitable cooling medi‐ Seawater
um Consult KAESER before using cooling water solutions.
Tab. 26 Cooler specification (option K2)
2.15.2 Cooling water quality

Oil may contaminate the cooling water if a leak occurs.
➤ A special heat exchanger must be used for heating drinking water.
The specific heat capacity and required flow rate of the cooling water changes if antifreeze is
added.
➤ Consult authorized KAESER Service representative to ensure optimum cooling-system
performance.
It is imperative that measures for cooling water treatment and filtration are implemented.
KAESER can provide the names of companies specializing in cooling water analysis and the supply
of suitable treatment plant.
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

12 BSD 9_5708 08 USE
2 Technical Data
2.16 Heat recovery
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
Tab. 27 Cooling water quality
2.16 Option W1/W2/W3

Heat recovery
2.16.1 Option W1
Prepared for external heat recovery
The quality of the heat transfer medium and its required flow rate depend on the type of heat
exchanger used.
Maximum permissible pressure loss in the cooling oil circuit: 8.7 psi.
Maximum heat capacity BSD 40 BSD 50 BSD 60

available*
[kW] 27.0 33.3 40.8
[MJ/h] 97 120 147
[kcal/h] 23216 28616 35082
* With the combination valve set to open at 176 °F.
Tab. 28 Heat capacity (option W1)
2.16.2 Option W2/W3

Internal heat recovery
Water is generally the heat-receiving medium. The water must meet the specification given below in
order not to damage the heat exchanger.

9_5708 08 USE BSD 13
2 Technical Data
2.16 Heat recovery
➤ Consult KAESER Service if you wish to use a different heat-receiving medium.
Water quality specification
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
Tab. 29 Water quality specification
Heat exchanger specification

Material 1.4401 1.4401 1.4401
Braze Copper (Cu) Copper (Cu) Copper (Cu)
Maximum working pres‐ 145 145 145
sure [psig]
(heat transfer medium)
Maximum permissible out‐ 212 212 212
let temperature [°F]
Unsuitable heat transfer Seawater
media Consult KAESER about water types.
Tab. 30 Heat exchanger specification (option W2/W3)

14 BSD 9_5708 08 USE
2 Technical Data
2.16 Heat recovery
Heat capacity
Maximum heat capacity BSD 40 BSD 50 BSD 60

available*
[kW] 27.0 33.3 40.8
[MJ/h] 97 120 147
[kcal/h] 23216 28616 35082
* With the combination valve set to open at 176 °F.
Tab. 31 Heat capacity (option W2/W3)
Option W2 Flow rate for heating from 113 °F to 158 °F (equivalent to ΔT = 45F)

Flow rate [gpm] 4.0 5.3 6.2
Pressure drop [psi] <2.9 <3.6 <3.6
Tab. 32 Flow rate / pressure loss (option W2)
Option W3 Flow rate for heating from 59 °F to 158 °F (equivalent to ΔT = 99F)

Flow rate [gpm] 1.8 2.2 2.6
Pressure drop [psig] <1.5 <2.2 <2.2
Tab. 33 Flow rate / pressure loss (option W3)

9_5708 08 USE BSD 15
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
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.
3.2 Specified use

The machine is intended solely for industrial use in generating compressed air. Any other use is
considered incorrect. The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
➤ 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.
➤ Do not use compressed for any application that will bring it into direct contact with food products
unless it is specifically treated.
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 or explosive gases or vapors.
➤ 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.

16 BSD 9_5708 08 USE
3.5 Dangers
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 recognize the possible dangers
involved.
Authorized 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 authorization to operate electrical and compressed air de‐
vices.
■ Additional qualifications for compressors with refrigeration dryers:
─ Adequate training and authorization on refrigeration devices.
Authorized 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 recognize the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ have received adequate training and authorization 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 recognize 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 authorized to
carry out their tasks.
3.4.3 Adhere to Inspection Schedules and Accident Prevention Regulations.

The machine is subject to local inspection schedules.
➤ Ensure that local inspection schedules are adhered to.
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.

9_5708 08 USE BSD 17
3.5 Dangers
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 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.
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 food products.
➤ Use food-grade cooling oil whenever compressed air is to come into contact with food products.
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.

18 BSD 9_5708 08 USE
3.5 Dangers
➤ 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 vapors or parts of the machine.
Noise
➤ Operate the machine only with full soundproofing.

➤ Wear hearing protection if necessary.
The safety 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.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapor.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
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 safety relief valves on air receivers and compressed air lines before
installing any new machines.
➤ If the blow-off capacity is insufficient:
Install safety relief valves with larger blow-off capacity.

9_5708 08 USE BSD 19
3.5 Dangers
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 center 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.
➤ 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 vapors,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulfide.
➤ 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 authorized groups for disposal.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organizational 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 authorized personnel may enter these areas.

20 BSD 9_5708 08 USE
3.6 Safety Devices
Activity Danger area Authorized personnel

Transport Within a 10 ft radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 3 ft radius of the machine and its supply
cables.
Operation Within a 3 ft radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 3 ft radius of the machine.
Tab. 34 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.
➤ 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 chapter 4, 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.

9_5708 08 USE BSD 21
3.7 Safety Signs
Fig. 2 Location of safety signs
Item Symbol Meaning

8 Danger of fatal injury from touching electrically live components!
➤ Switch off and lock out the supply disconnecting device and check that no voltage
is present.
9 Machine starts automatically!
Severe injury could result from rotating components, electrical voltage and air pres‐
sure.
➤ Isolate from the power supply and lock out before opening any machine enclosure
or guard.
11 Injury and/or contamination can result from breathing compressed air!
Contamination of food can result from using untreated compressed air for food proc‐
essing!
➤ Never breathe untreated compressed air.
➤ Air from this compressor must meet OSHA 29CFR1910.134 and
FDA 21CFR178.3570 standards, if used for breathing or food processing. Use
proper compressed air treatment.
13 Hot surface can cause burns!
➤ Let the machine cool down.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
16 Wrong cooling oil level can cause machine defects or rising oil consumption (oil con‐
max.
min.
tent for pure air)!
➤ Check the oil level regularly and top up as necessary.

22 BSD 9_5708 08 USE
3.8 Emergencies
Item Symbol Meaning

23 Serious injury or death can result from loosening or opening component that is under
pressure and heavily spring loaded!
➤ Do not open or dismantle the valve.
➤ Call for authorized KAESER Service representative if a fault occurs.
24 Serious injury or death can result from loosening or opening component under pres‐
sure!
➤ De-pressurize all pressurized components and enclosures.
➤ Secure that machine keeps de-pressurized.
➤ Check that machine is de-pressurized.
25 Ear damage and burns can result from loud noise and/or oil mist when the safety relief
valve opens!
➤ Wear ear protection and protective clothing.
➤ Close all access doors and cover panels.
27 Risk of electric shock!
If the interrupter has tripped current-carrying components of the controller should be
examined and replaced if damaged to reduce the risk of fire or electric shock.
28 Risk of electric shock!
To maintain overcurrent short-circuit, and ground-fault protection, the manufacturer's
instructions for setting the interrupter must be followed to reduce the risk of fire or
electric shock.
Tab. 35 Safety Signs
3.8 Emergencies
3.8.1 Correct fire fighting
Suitable extinguishing agents:
■ Foam
■ Carbon dioxide
■ Sand or dirt
Unsuitable extinguishing agents:

■ Strong jet of water
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

9_5708 08 USE BSD 23
3.9 Warranty
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.
3.8.2 Remove any cooling oil from your person

➤ Eye contact:
Rinse eyes 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.
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorized 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.

24 BSD 9_5708 08 USE
4.1 Enclosure

4.1 Enclosure
Fig. 3 Enclosure overview

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
The enclosure is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ As resting place or storage of any kind of load.
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_5708 08 USE BSD 25
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.

26 BSD 9_5708 08 USE
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 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
4.4.3 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.

9_5708 08 USE BSD 27
4.4 Options
Fig. 7 Water-cooling (option K2)

1 Oil cooler 3 Cooling water connection
2 Air cooler 4 Cooling water connection
4.4.4 Option W1/W2/W3

Heat recovery
The cooling oil circuit includes 2 valves that regulate the oil temperature.
■ Combination valve: oil temperature regulator for the oil cooler.
■ Thermostatic valve: oil temperature regulator for the heat recovery system.
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.
Option W1 Prepared for external heat recovery
Connections are provided for an external system to recover surplus heat.

The thermostatic valve does not function when the machine is delivered. The necessary working
element must be installed when installing the heat recovery system.
If necessary, the working element in the combination valve can be exchanged for one with higher
opening temperature. The opening temperature depends on operating and ambient conditions.
Working elements are marked with their opening temperature [°C].
If the cooling oil temperature is too low, condensate can form and damage the machine.
➤ Consult KAESER Service on components and layout to ensure a fully functioning cooling
and heat recovery system.
Option W2/W3 Internal heat recovery
A plate-type heat exchanger is installed for internal heat recovery.

The plate-type heat exchanger transfers heat from the cooling oil to a heat-receiving medium.

28 BSD 9_5708 08 USE
4.5 Operating modes and control modes
Both oil temperature regulators are equipped with working elements that ensure trouble-free func‐
tioning of the cooling and heat recovery systems.
Fig. 8 Internal heat recovery (option W2/W3)

1 Plate-type heat exchanger

4.5.1 Operating modes
The machine operates in the following modes:
■ LOAD:
The inlet valve is open. The airend delivers compressed air to the distribution network.
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
distribution network. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting valve.
The compressor motor runs without load and draws little current.
■ STANDSTILL:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the
distribution network. The oil separator tank is vented.
The compressor motor is stopped.
Option C1 ■ MODULATING CONTROL:
With the help of a control valve (the proportional controller) the degree of opening of the inlet
valve is steplessly varied in response to the air demand. The airend delivers compressed air to
the distribution network.
The load and power consumption of the drive motor rises and falls with the air demand.
The regulating valve is factory set. The setting should not be changed without consultation with
KAESER SERVICE.
4.5.2 Control modes

In order to maintain system pressure between the set minimum and maximum values and to com‐
pensate for the compressed air drawn at any time, the controller will switch the compressor motor
between the various operating states according to specific rules (specified by the control mode). The
control mode also rules the degree of energy efficiency of the machine.
SIGMA CONTROL can work in the following control modes:

■ DUAL
■ QUADRO

9_5708 08 USE BSD 29
■ VARIO
Option C1 ■ MODULATING control
Energy-efficient control modes for various applications:

Application Recommended
control mode
Compressed air station with one machine or several machines with compa‐ VARIO
rable delivery
Machine for peak load in a compressed air station DUAL
Machine for intermediate load in a compressed air station VARIO
Machine for basic load in a compressed air station QUADRO
Tab. 36 Energy-efficient control modes
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.
Option C1 MODULATING control
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).
Compressed air demand Operating modes

rises MODULATING
LOAD

30 BSD 9_5708 08 USE
4.6 Safety Devices
Compressed air demand Operating modes

falls MODULATING
IDLE
STANDSTILL
Tab. 37 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.
■ Safety relief valve:
The pressure relief valve protects the machine from excessive pressure. It is preset at the factory.
■ Enclosures and guards for moving parts and electrical connections
These protect against accidental contact.
4.7 SIGMA CONTROL Keys and Indicators
Fig. 9 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.

9_5708 08 USE BSD 31

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.
10 «Events and Displays the event memory.
information» 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. 38 Keys
Fig. 10 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.

32 BSD 9_5708 08 USE

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. 39 Indicators

9_5708 08 USE BSD 33
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 vapors or parts of the machine.
➤ The machine is not explosion protected!
Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
➤ Ensure that required ambient conditions are maintained with regard to:
■ Ambient temperature and humidity
■ clean inlet air with no damaging contaminants,
■ explosive or chemically unstable gases or vapors,
■ acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulfide.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Keep suitable fire extinguishing agents ready for use.
5.2 Installation conditions

5.2.1 Determining location and clearances
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.

34 BSD 9_5708 08 USE
5.2 Installation conditions
Fig. 11 Recommended machine placement and dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z 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 +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.
5.2.2 Ensure adequate ventilation.

If the ventilation is insufficient, a partial vacuum can be created in the 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 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_5708 08 USE BSD 35
5.3 Using the Compressor to Supply A Compressed 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 motorized ventilation flaps and louvers on variable frequency drive (SFC) machines.
Flaps or shutters that are opened by the action of 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 Using the Compressor to Supply A Compressed Air System.

When the machine is connected to a compressed air system, the system operating pressure must
not exceed 232 psig.
Initial filling of a fully vented air network generally creates a very high rate of flow through air treatment
devices. These conditions are detrimental to correct treatment. Air quality suffers.
To ensure maintenance of desired air quality when filling a vented compressed air system we rec‐
ommend the installation of an air main charging system.
➤ Please allow KAESER to advise on this subject.

36 BSD 9_5708 08 USE
6 Installation
6.1 Safety
6 Installation
6.1 Safety
The following instructions must be followed 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 electrically conducting components
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.
Working on pressure systems
1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
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.
Working on the drive
2. Do not open the enclosure while the machine is switched on.
Further information Specification of authorized personnel is found in chapter 3.4.2.

Specification of dangers and their avoidance is 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_5708 08 USE BSD 37
6 Installation
6.4 Making the Power Supply Connection
Fig. 12 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 The power supply disconnecting device is switched off
The disconnecting device is locked in the off position
A check has been made to ensure no voltage is present
1. Have the electrical connections carried out by authorized personnel only.

2. Carry out protection measures as stipulated in relevant regulations (IEC 364 or example) and in
national accident prevention regulations. In addition, the regulations of the local electricity supplier
must be observed.
3. Test the overload protection cut-out to ensure that the time it takes to disconnect in response to
a fault is within the permitted limit.
4. Use supply conductors and fuses in accordance with local regulations.
5. The user must provide the machine with a lockable supply disconnecting device.
This could be, for example, a switch-disconnector with fuses. If a circuit breaker is used it must
be suitable for the motor starting characteristics.
6. Check that the correct taps on the control voltage transformer are connected according to the
supply voltage.
If this is not correct, change the connection to suit the power supply voltage.
DANGER
Danger of fatal injury from electric shock!
➤ Switch off and lock out the supply disconnecting device and check that no voltage is present.
7. Connect the power supply.
Further information The electrical diagram 13.4 contains further specifications for electrical connection.

38 BSD 9_5708 08 USE
6 Installation
6.5 Options
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.
Fig. 13 Connecting the cooling water

A Cooling water outlet 12 Connection port with plug
B Cooling water inlet 17 Pressure relief valve
10 Shut-off valve
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.
Blow-off pressure and capacity are governed by the user's installation design. The technical
specification of the cooler must be taken into account.
2. Connect the cooling water lines to the fittings.
3. Open the shut-off valve on the cooling water outlet A .

9_5708 08 USE BSD 39
6 Installation
6.5 Options
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.
6.5.3 Option W1/W2/W3

Connecting the heat recovery system
➤ Take the electrochemical series into account and choose suitable materials for connections.
➤ Keep the effect of pressure surges on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a pulsation damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.
➤ Avoid very low inlet temperatures of the heat transfer medium as it can cause condensation.
If required, contactKAESER for suitable insulation measures.
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.

40 BSD 9_5708 08 USE
6 Installation
6.5 Options
6.5.3.2 Option W2/W3

Connecting the internal heat recovery system
Connecting the internal heat recovery system
Fig. 14 Connecting the heat recovery system

A Outlet 12 Connection port with plug
B Inlet 17 Pressure relief valve
10 Shut-off valve
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.
Blow-off pressure and capacity are governed by 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.

9_5708 08 USE BSD 41
7 Initial Start-up
7.1 Safety
7 Initial Start-up
7.1 Safety
The following instructions must be followed for safe machine commissioning.
Basic safety instructions

2. Commissioning may only be carried out by authorized personnel.
Working on electrically conducting components.
1. Close shut off valves or otherwise isolate the machine from the compressed air system to ensure

7.2 To be noted before commissioning

Incorrect or improper commissioning can cause injury to persons or damage to the machine.

42 BSD 9_5708 08 USE
7 Initial Start-up
7.3 Checking installation and operating conditions
➤ Commissioning of the machine may only be carried out by trained and authorized installation or
maintenance personnel.
Special measures for re-commissioning after storage
Storage period Remedy

longer than...
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorized KAESER Service repre‐
sentative.
36 months ➤ Have the overall technical condition checked by an authorized KAESER Ser‐
vice representative.
Tab. 40 Re-commissioning 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 Confirmed?

chapter
➤ Are the operators fully familiar with safety regulations? –
➤ Have all the positioning 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 name‐ 2.1
plate?
➤ Are the power supply cable conductor cross-sections and fuse ratings 2.14
adequate?
➤ Drive motor overload protection switch set according to the main power 7.4
supply voltage?
➤ Fan motor overload protection switch set according to the main power 7.5
supply voltage?
➤ 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?
➤ Sufficient cooling oil in the separator tank? 10.13
(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)
➤ Supply of cooling water ensured? 6.5.2
(option K2)

9_5708 08 USE BSD 43
7 Initial Start-up
7.4 Setting the overload protection cut-out
To be checked See Confirmed?

chapter
➤ Are all access doors closed and latched and all removable panels in –
place and secured?
Tab. 41 Installation and operating conditions checklist
7.4 Setting the overload protection cut-out

Electrical diagram 13.4 gives the location of the overload protection cut-out.
With star-delta starting, the phase current is fed via the overload protection cut-out. This phase current
is 0.58-times the rated motor current.
To prevent the overload protection cut-out from being triggered by voltage fluctuations, temperature
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 KAESER Service.
7.5 Setting the motor overload protection switch

Electrical diagram in chapter 13.4 gives the setting values for 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 motor overload protection switch from being triggered by voltage fluctuations,
temperature influences or component tolerances, the setting can be higher than the rated motor
current.
➤ Check the motor overload protection switch setting.
The overload protection switch shuts the machine down despite being correctly set?
➤ Contact KAESER Service.
7.6 Filling 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 manually add a quantity of cooling oil into the airend. In order
to avoid that the cooling oil exceeds the permissible level, drain the required quantity from the dep‐
ressurized oil separator tank.
Chapter 10.16 provides detailed information on how to drain cooling oil from the oil separator tank.
Material 1 quart Cooling oil from separator tank
Precondition The supply disconnecting device is switched off,

the device is locked off,
the absence of voltage has been verified.
The machine is fully vented, the pressure gauge on the oil separator tank reads 0 psig.

44 BSD 9_5708 08 USE
7 Initial Start-up
7.7 Checking direction of rotation
Fig. 15 Inlet valve filling port

1 Remove 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.
Fig. 16 Coupling
1 Compressor block 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
1. Remove the safety screen 3 .

2. Turn the airend 4 by turning the coupling 1 by hand in the direction indicated by the arrow 2 .
3. Replace the safety screen 3 .
7.7 Checking 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, the machine can be started very briefly and the rotation direction of the motor cooling
fans noted.
1. Check the direction of phase rotation with a phase sequence meter.
2. If the direction is incorrect, reverse 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.

9_5708 08 USE BSD 45
7 Initial Start-up
7.8 Starting the machine for the first time
7.8 Starting the machine for the first time

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

2. Switch on the main power supply disconnecting device.
After the controller has carried out a self-test, the green LED Power ON lights.
3. As required
Change the display language as described in chapter 7.10.
4. Press the «LOAD/IDLE» toggle key.
The green LED IDLE lights.
5. Press the «ON» key.
The green LED Machine ON lights and the machine runs in IDLE. This ensures that cooling oil
is distributed throughout the machine.
6. After allowing the machine to IDLE for at least 1 minute:
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, all screw-type electrical connections should be checked
and tightened if necessary.
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.

46 BSD 9_5708 08 USE
7 Initial Start-up
7.10 Changing the display language
Fig. 17 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
2 If required: as necessary to reach the required lan‐
Acknowledge alarm message. guage.
3 Depress the «escape» key for 5 seconds to 7 Press «enter» to select the language.
change to the main menu. 8 Depress the «escape» key for 5 seconds to
4 Press the «UP» key 8 times. change to the main menu.
➤ Change the display language on SIGMA CONTROL as required.

9_5708 08 USE BSD 47
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.
The power supply disconnecting device has been installed by the user.
Fig. 18 Switching on and off

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

After the controller has carried out a self-test, the green LED Power ON lights.
2. Press the «ON» key.
The green LED Machine ON lights.
If a power failure occurs, the machine is not prevented from automatic re-starting.
It can re-start automatically as soon as power is restored.
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.

48 BSD 9_5708 08 USE
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 power supply. The Controller ON LED extin‐
guishes.
8.2 Switching Off in an Emergency and Switching On again

The EMERGENCY STOP pushbutton is located below the control panel.
Fig. 19 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 Switching on and off from a remote control center

Precondition A link to the remote control center exists.

9_5708 08 USE BSD 49
8 Operation
8.4 Switching on and off with the clock
Fig. 20 Switching on and off from a remote control center

1 «Remote control» key
2 Remote control LED
1. Attach an easily seen notice to the machine that warns of remote operation.
Remote control: danger of unexpected starting!

➤ Make sure the power supply disconnecting device is switched off before commencing any work
on the machine.
Tab. 42 Machine identification
2. Label the starting device in the remote control center as follows:
Remote control: danger of unexpected starting!

➤ Before starting, make sure that no one is working on the machine and that it can be safely started.
Tab. 43 Remote control identification
3. Press the «remote control» key.

The remote control LED lights. The machine can be remotely controlled.
8.4 Switching on and off with the clock

Precondition The clock is programmed.

50 BSD 9_5708 08 USE
8 Operation
8.5 Acknowledging alarm and warning messages
Fig. 21 Switching on and off with the clock

1 «Clock» key
2 Clock LED
1. Attach an easily seen notice warning of time-controlled operation:
Clock control: danger of unexpected starting!

➤ Make sure the power supply disconnecting device is switched off before commencing any work
on the machine.
Tab. 44 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

9_5708 08 USE BSD 51
8 Operation
Fig. 22 Acknowledging messages

10 Warning LED (yellow)
11 Alarm LED (red)
12 «Acknowledge» key
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.
Precondition The fault has been rectified
➤ Acknowledge the message with the «acknowledge» key.

alarm LED extinguishes.
The machine is ready for operation again.
If the machine has been shut down with the «EMERGENCY STOP» pushbutton:
➤ Unlatch the «EMERGENCY STOP» pushbutton (turn in direction of the arrow) before ac‐
knowledging the alarm message.
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.
Precondition The danger of an alarm is passed,

maintenance has been carried out.
➤ Acknowledge the message with the «acknowledge» key.

The warning LED extinguishes.
Further information A list of possible warning messages occurring during operation are shown in chapter 9.3.

52 BSD 9_5708 08 USE

The following tables are intended to assist in locating causes of 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 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.
9.2 Alarm messages (machine stop)

Message Possible cause Remedy
blowoff prot. ⇞ The activating pressure of the pressure Change the oil separator cartridge.
relief valve on the oil separator tank has Open the shut-off valve in the venting
been exceeded. line.
AI1 open cct. Analog input open circuit. Check line and connections.
AI2 open cct. Short to earth.
AI1 short cct. The connection between the sensor Check line and connections.
AI2 short cct. 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.
AI5 open cct. Analog input open circuit. Check line and connections.
AI6 open cct. Short to earth.
AI5 short cct. The connection between the sensor Check line and connections.
AI6 short cct. 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 Compressor model uncertain Call KAESER Service.
PD T⇞ Package discharge (PD) temperature Check the cooling oil level.
too high. Clean the cooler.
Check the fan motor.
PD T⇟ Package discharge (PD) temperature Call KAESER Service.
too low.
DO0.6/DO0.7 I⇞ Short circuit in the line between the dig‐ Check line and connections.
ital output and the consumer.

9_5708 08 USE BSD 53

DO1.6/DO1.7 I⇞ Short circuit in the line between the dig‐ Check line and connections.
ital output and the consumer.
airend rotation The drive motor is turning in the wrong Changeover phase lines L1 and L2.
direction.
error: RS485-USS Fault in the data transfer with USS pro‐ Cable between the SIGMA CONTROL
tocol (RS485) between the and the frequency converter.
SIGMA CONTROL and the frequency Check the cable shielding.
converter.
ext. message 0 Customer specific: Remove the fault in the connected com‐
ext. message 1 component connected reports a fault ponent.
ext. message 2
ext. message 3
ext. message 4
ext. message 5
FC Frequency converter faulty. Call KAESER Service.
back press. run Drive belts or coupling broken. Drive belts:
Replace drive belts.
Coupling:
Call KAESER Service.
back press. stop 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.
no press.buildup The machine produces no compressed Check the machine for leaks.
air. Check coupling / V-belts
The working pressure does not rise Call KAESER Service.
above 3.5 bar within the preset period.
comp. T ⇟ Thermostatic valve defective Call KAESER Service.
condensatedrain The condensate drain is defective. Refrigeration dryer: check condensate
drainage.
RD condens.drain Refrigeration dryer: Refrigeration dryer
The condensate drain is defective. Check the condensate drain.
RD p⇞ Refrigeration dryer: Clean the refrigerant condenser.
pressure too high in the refrigerant cir‐ Check the fan motor.
cuit.
Maintain operating conditions.
Safety pressure switch tripped.
RD p⇟ Refrigeration dryer: Call KAESER Service.
refrigerant lost; pressure in the refriger‐
ant circuit too low. Inlet pressure switch‐
ed tripped.
RD T⇟ Refrigeration dryer: Call KAESER Service.
Compressed air temperature too low.
WC water volume Cooling water pressure is too low. Check cooling water supply.
Cooling water stop valve:
Check open/closed.
WC – –

54 BSD 9_5708 08 USE

fan M2 I⇞ Overload shut-down of the first fan mo‐ Investigate cause of shut-down.
tor. Reset overload protection cut-out.
fan M3 I⇞ Overload shut-down of the second fan Investigate cause of shut-down.
motor. Reset overload protection cut-out.
fan M4 I⇞ Overload shut-down of the third fan mo‐ Investigate cause of shut-down.
tor. Reset overload protection cut-out.
fan M7 I⇞ Overload shut-down of the control cab‐ Investigate cause of shut-down.
inet fan motor. Call KAESER Service.
motor bearings Drive motor bearings overheated. Re-grease the motor bearings.
motor I⇞ Overload shut-down of the compressor Investigate cause of shut-down.
drive motor. Change the oil separator cartridge.
motor T⇞ Compressor drive motor overheated. Clean the motor.
Keep ambient conditions within speci‐
fied limits.
mains cont. off? Main contactor not dropping out. Check main contactor and wiring.
mains cont. on? Main contactor not pulling in. Check main contactor and wiring.
mains voltage ⇟ Second power failure. Check power supply voltage.
Check the door interlock switch.
mains monitor Fault in main power supply. Have the main power supply checked.
emergency stop EMERGENCY STOP pushbutton Unlatch the pushbutton.
pressed.
OS dp⇞ Oil separator cartridge clogged. Change the oil separator cartridge.
OS T⇞ Maximum air temperature at the oil sep‐ Check the line to the trip relay.
arator 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 pressure Change the pressure relief valve.
relief valve on the oil separator tank has
been exceeded.
oil content ⇞ The oil content limit for pure air has Change the oil separator cartridge.
been exceeded.

9_5708 08 USE BSD 55
9.3 Warning messages (yellow LED lights)

Sigma Control T⇞ The maximum permissible Keep ambient conditions within speci‐
SIGMA CONTROL housing tempera‐ fied limits.
ture has been exceeded. Control cabinet:
Check filter mats and fan.
softstart Fault in the soft start equipment. Call KAESER Service.
start T⇟ Airend discharge temperature (ADT) Keep ambient conditions within speci‐
too low. fied limits.
Ambient temperature <+37°F
T-switch Customer specific: –
ADT dT/dt ⇞ The rate of rise of the airend discharge Check the cooling oil level.
temperature (ADT) is too fast. Call KAESER Service.
ADT ⇞ Maximum permissible airend discharge Keep ambient conditions within speci‐
temperature (ADT) exceeded. fied limits.
Clean the cooler.
Check the cooling oil level.
access doors Door open / interlocked panel removed Fit and secure all panels and close ac‐
while the machine is running. cess doors.
Tab. 45 Alarm messages and measures

blowoff prot. ↑ The pressure relief valve's activat‐ Change the oil separator cartridge.
ing pressure will soon be reached. Open the shut-off valve in the venting line.
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.

56 BSD 9_5708 08 USE

error: RS485-PP Wrong configuration or transmis‐ Check the link/interface connections be‐
sion error. tween the two controllers.
Check maximum cable length and screen‐
ing.
1 master and 1 slave configured.
error: SMS SMS can not be sent. Call KAESER Service.
ext. message 0 Customer specific: Carry out maintenance on connected com‐
ext. message 1 Connected component initiates a ponent.
ext. message 2 maintenance message.
ext. message 3
ext. message 4
ext. message 5
FC AI1 fault SFC machine: Call KAESER Service.
Network pressure sensor on AI1 de‐
fective.
FC MM service SFC machine: Deactivate the service mode as soon as the
Frequency converter service mode. frequency converter settings are complet‐
ed.
FC mains SFC machine: Check power supply.
Frequency converter power supply
failed.
annual maint Last maintenance was 1 year ago. Carry out the necessary maintenance and
reset the corresponding maintenance inter‐
val 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.
comp. T ↓ The airend discharge temperature Call KAESER Service.
(ADT) did not reach the minimum
value within the specified time.
condensatedrain The condensate drain is defective. Check the condensate drain and drain line.
RD condens.drain Refrigeration dryer: Check the condensate drain.
The condensate drain is defective.
RD p↑ Refrigeration dryer: Clean the refrigerant condenser.
pressure too high in the refrigerant Check the fan motor.
circuit.
Maintain operating conditions.
Safety pressure switch tripped.
RD p↓ Refrigeration dryer: Call KAESER Service.
refrigerant lost; pressure in the re‐
frigerant circuit too low. Inlet pres‐
sure switched tripped.

9_5708 08 USE BSD 57

RD T↑ Refrigeration dryer: Maintain operating conditions.
Compressed air temperature too Clean the refrigerant condenser.
high.
Clean the cooler.
Install an extractor fan.
RD T↓ Refrigeration dryer: Call KAESER Service.
Compressed air temperature too
low.
bearing lube h⇞ The maintenance interval for re- Re-grease the motor bearings.
greasing the bearings has expired.
motor bearing h⇞ The maintenance interval for check‐ Have the motor bearings checked by an au‐
ing the compressor drive motor thorized KAESER Service Technician.
bearings has expired.
ext.load signal? Uncertain external load signal: Check settings of the external controller.
The high cut-out pressure was ex‐ Take into account pressure drops across
ceeded. filters and dryer.
The external load control has not
switched to idle.
fan bearing h⇞ The maintenance interval for check‐ Have the motor bearings checked by an au‐
ing the fan motor bearings has ex‐ thorized KAESER Service Technician.
pired.
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 the air filter.
check has elapsed.
modem problem SIGMA CONTROL does not recog‐ Check the link between
nise the modem. SIGMA CONTROL and the modem.
motor bearings Drive motor bearing defective. Call KAESER Service.
motor T↑ Drive motor overheating. Clean the motor.
Keep ambient conditions within specified
limits.
motor starts /d⇞ The permissible number of motor Extend the idle period.
starts was exceeded in the last Increase the capacity of air receiver.
24 hours.
Increase cross-section of piping between
compressor and air receiver.
motor starts /h⇞ The permissible number of motor Extend the idle period.
starts was exceeded in the last Increase the capacity of air receiver.
60 minutes.
Increase cross-section of piping between
compressor and air receiver.
system press. ↑ Network pressure is above the Check for air leaks.
"sys.press. high" value. Check the 'sys.press. high' warning setting.
Check if the machine switches to LOAD.
system press. ↓ Network pressure has fallen below Check air demand.
the set 'low' value. Check cable runs and sensor connections.
Air consumption too high. Check the 'sys.press. low' warning setting.

58 BSD 9_5708 08 USE

mains voltage ↓ 1. Power supply failure: Check power supply.
Machine was re-started automati‐ Check the door interlock switch.
cally.
OS dp↑ The pressure drop across the oil Change the oil separator cartridge.
separator cartridge has risen.
Oil separator cartridge clogged.
OS h⇞ The oil separator cartridge change Change the oil separator cartridge.
interval has expired.
oil filter dp ↑ The pressure drop across the oil fil‐ Change the oil filter.
ter has risen.
Oil filter clogged.
oil level ↓ Cooling oil level too low. Top up the cooling oil.
oil T↓ Cooling oil temperature too low. Check temperature switch, line and con‐
nection.
Check the oil circulation.
Increase room temperature.
oil change h⇞ The interval for the oil change has Change the cooling oil.
expired.
oil filter h⇞ The oil filter change interval has ex‐ Change the oil filter.
pired.
p-switch Customer specific: –
buffer battery Data retention battery is almost dis‐ Change the battery.
charged.
oil content ↑ The oil content limit for pure air will Check the scavenge tube in the oil separa‐
soon be reached. tor cartridge.
Check the dirt trap strainer in the scavenge
line.
Check air treatment upstream of the meas‐
uring point.
V-belt tension Belt tension is too low. Re-tension drive belts.
blt.coup.insp.h⇞ The belt tension / coupling inspec‐ Carry out a visual check.
tion interval has expired. Re-tension drive belts.
blt.coup.insp.h⇞ The belts/coupling change interval Drive belts:
has expired. Check drive belts.
Coupling:
start T↓ The airend temperature is too low (< Keep ambient conditions within specified
+37 °F). limits.
start T↓↓ The airend temperature is too low Keep ambient conditions within specified
(<14 °F) for the machine to be op‐ limits.
erated.
T-switch Customer specific: –

9_5708 08 USE BSD 59
9.4 Other Faults

TRAP Interrupts System message Call KAESER Service.
valve insp. h⇞ The motor bearings checking inter‐ Call KAESER Service.
val has expired.
ADT ↑ Maximum airend discharge temper‐ Clean the cooler.
ature (ADT) almost reached. Check the cooling oil level.
Replace the oil filter.
Ensure adequate ventilation.
Keep surrounding temperature within rec‐
ommended limits.
access doors Doors opened with the machine Close access doors.
stopped.
Tab. 46 Warning messages
9.4 Other Faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call authorized KAESER Ser‐
compressed air. opening partially. vice representative.
Venting valve not closing. Call authorized KAESER Ser‐
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 authorized KAESER Ser‐
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.

60 BSD 9_5708 08 USE
9.4 Other Faults
Fault Possible cause Remedy

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 authorized KAESER Ser‐
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. 47 Other faults and actions

9_5708 08 USE BSD 61
10 Maintenance
10.1 Safety
10 Maintenance
10.1 Safety
The following instructions must be followed for safe machine maintenance.
Basic safety instructions

2. Maintenance work may only be carried out by authorized personnel!
Working on electrically conducting components.
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.


62 BSD 9_5708 08 USE
10 Maintenance
10.2 Maintenance schedule

10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for average operating conditions.
➤ In adverse conditions, perform maintenance work at shorter intervals.
Adverse conditions are, e.g.:

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ 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.
Further information A list is given in chapter10.19.
10.2.2 Resetting maintenance interval counters

Depending on the components installed, 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 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.
10.2.3 Regular maintenance tasks

The table below lists maintenance tasks required.
➤ 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 10.13
Control cabinet: 10.4
check the filter mat
Up to 1,000 h Clean the cooler 10.5
Check the cooling air filter mat 10.3
h = operating hours

9_5708 08 USE BSD 63
10 Maintenance
Interval Maintenance task See chapter

Up to 3,000 h Change the cooling air filter mat 10.3
Control cabinet: 10.4
change the filter mat
SIGMA CONTROL dis‐ Change the air filter element 10.8
play Motor bearing maintenance 10.9
Check the coupling 10.10
SIGMA CONTROL dis‐ Change the oil filter 10.17
play
At least annually
SIGMA CONTROL dis‐ Change the oil separator cartridge 10.18
play
At the latest every 3 years
Variable (see table 49) Change the cooling oil 10.16
Annually Check the safety relief valve 10.11
Check the overheating safety shutdown function 10.12
Check the cooler for leaks 10.5
Water-cooling maintenance 10.6
Heat recovery system maintenance 10.7
Check that all electrical connections are tight –
h = operating hours
Tab. 48 Regular maintenance tasks
10.2.4 Cooling oil changing interval

Machine utilization and ambient conditions are important criteria for the number and length of the
change intervals.
Authorized KAESER Service representative will support you in determining appropriate inter‐
vals and provide information on the possibilities of oil analysis.
➤ 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

64 BSD 9_5708 08 USE
10 Maintenance
10.3 Cleaning or Renewing the Cooling Air Filter Mat
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
Tab. 49 Oil change intervals lubricants
10.2.5 Regular service tasks

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

Up to 12,000 h Have the valves checked.
Up to 12,000 h Fan motor:
At the latest every 3 years Have the bearings checked.
Up to 36,000 h Have hose lines replaced.
At the latest every 6 years
Up to 36,000 h Drive motor:
At the latest every 8 years Have the bearings checked.
h = operating hours
Tab. 50 Regular service tasks
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.
Material Warm water and household detergent

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

9_5708 08 USE BSD 65
10 Maintenance
10.4 Cleaning or Replacing the Control Cabinet Filter Mats
Fig. 23 Cooling air filter mat

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

by turning 90° counter clockwise with a screwdriver.
2. Remove the frame 2 .
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out 5 times.
➤ Beat the mat 1 or use a vacuum cleaner to remove loose dirt.

If necessary, wash the mat in lukewarm water (about 100 °F) 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 disconnect device is locked in the off position,
a check has been made that no voltage is present.
The machine has cooled down.

66 BSD 9_5708 08 USE
10 Maintenance
10.5 Cooler Maintenance
Fig. 24 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 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.
Material Brush and vacuum cleaner.

Breathing mask (if required).
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.

9_5708 08 USE BSD 67
10 Maintenance
10.6 Water-cooling Maintenance
Fig. 25 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 representa‐
tive.
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 representative.
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.

Check for leaks
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.

68 BSD 9_5708 08 USE
10 Maintenance
10.7 Maintain the heat recovery system
1. Check the cooler visually for leaks.

2. Have an authorized KAESER Service representative check the cooler for internal leaks at least
once a year.
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 Option W1/W2/W3

Maintain the heat recovery system
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.
➤ Have the external heat recovery system checked annually by KAESER Service.
10.7.1 Option W1
External heat recovery system
➤ Have the external heat recovery system checked annually by KAESER Service.
10.7.2 Option W2/W3

Internal heat recovery
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-receiving medium. Increased cooling oil loss can indicate a leaking
heat exchanger.
Precondition The power supply isolating device is switched off,

1. Check the heat exchanger visually for leaks.

2. Have KAESER Service check the heat exchanger for internal leaks and clean if contaminated.
10.8 Air Filter Maintenance

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.
Do not clean the air filter element with liquids.
Material Replacement part


9_5708 08 USE BSD 69
10 Maintenance
10.9 Motor Maintenance
Fig. 26 Air filter maintenance

1 Nut 3 Cover
2 Air filter element 4 Nut
Opening the air filter housing
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.
Cleaning the air filter element by tapping
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.
Cleaning the filter element with compressed air
➤ Use dry compressed air at less than 70 psig to blow dirt from the air filter element from inside to
outside.
Closing the air filter housing
1. Clean all parts and sealing surfaces.

2. Insert the air filter cartridge in the cover and secure with the nut 1 .
3. Insert the cover in the machine and secure with nuts 4 .
4. Close all access doors and replace all enclosure panels.
5. Switch on the power supply and reset the maintenance interval counter.
10.9 Motor Maintenance

Use only the high temperature grease EXXON UNIREX N3 for the motor bearings. Bearing
damages caused by the use of other brands of grease are excluded from the warranty.
Material Bearing grease EXXON UNIREX N3

Cleaning rags

70 BSD 9_5708 08 USE
10 Maintenance
10.10 Checking the Coupling
WARNING
Danger of burns from hot components.
➤ Wear long-sleeved clothing and gloves.
➤ Work with caution.
Drive motor
The motor bearings are fitted with grease nipples.

Apply the quantity of grease as stated on the motor nameplate.
Precondition Motor running
Fig. 27 Drive motor maintenance

1 Grease nipple
1. Clean the nipple with a rag before greasing.

2. Grease both bearings with a grease gun.
3. Close all access doors, replace and secure all removable panels.
4. Reset the maintenance interval counter
Option K1 Fan motor
➤ Have the motor bearings checked by a KAESER Service representative.
Option K2 Fan motor
➤ Have the fan motor bearings checked by a KAESER Service representative during the course of
a visit.
10.10 Checking the Coupling

A defective coupling is recognizable by:
■ noisy running,

9_5708 08 USE BSD 71
10 Maintenance
10.11 Checking the Safety Relief Valve
■ 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.
Fig. 28 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 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.
10.11 Checking the Safety Relief Valve

In order to check the safety relief valve, the machine's working pressure is raised above the blowoff
pressure of the valve.

72 BSD 9_5708 08 USE
10 Maintenance
10.12 Checking the Overheating Safety Shutdown Function
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.
Precondition The machine is switched off.

Password level 4 is activated.
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.
10.12 Checking the Overheating Safety Shutdown Function

The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F.
➤ Check the safety shutdown function as described in the SIGMA CONTROL manual.
The machine does not shut down?
➤ Have the safety shutdown function checked by an authorized KAESER Service represen‐
tative.
10.13 Checking the Cooling Oil Level

In frequency-controlled compressors (SFC) the oil level indicator is only accurate when the
machine is running at or near maximum speed.
The higher the speed, the lower the pressure at the compressed air outlet. The
SIGMA CONTROL displays this valve.
Precondition The machine has been running at least 5 minutes under LOAD.

9_5708 08 USE BSD 73
10 Maintenance
10.14 Venting the machine (depressurizing)
Fig. 29 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum level
WARNING
Danger of burning from hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.
➤ Check the oil level with machine running.
Result Top up when the indicator shows minimum level.

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

■ Isolate the compressor from the compressed air system.
■ Vent air from the oil separator tank.
■ Vent air manually from the air cooler.
Material The hose coupling, shut-off valve and maintenance hose lie beneath the oil separator tank.

A check has been made no voltage is present
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.

74 BSD 9_5708 08 USE
10 Maintenance
Fig. 30 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/fitting 8 Maintenance hose
Isolate the machine from the compressed air system.
➤ 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.
Vent air from the oil separator tank.
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.
Vent air manually from the air cooler.
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 .

9_5708 08 USE BSD 75
10 Maintenance
10.15 Topping up the Cooling Oil
2. Slowly open the shut-off valve 7 to release pressure.

3. Withdraw the male hose fitting 6 and close the shut-off valve 7 .

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

Fig. 31 Topping up the Cooling Oil

1 Hose coupling (air cooler venting) 6 Male hose coupling/fitting
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 10.15.1.

2. Fill with cooling oil and test run as described in 10.15.2.
10.15.1 Venting the Machine (depressurizing)

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

■ Isolate the compressor from the compressed air system.
■ Vent air from the oil separator tank.
■ Vent air manually from the air cooler.

76 BSD 9_5708 08 USE
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 compressed air system
➤ 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.
Vent air from the oil separator tank
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.
Vent air manually from the air cooler
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.
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 .
10.15.2 Top up with cooling oil and test run

Topping up the Cooling Oil
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.

9_5708 08 USE BSD 77
10 Maintenance
10.16 Changing the cooling oil
1. Unscrew the filler plug 4 slowly.

2. Top up to bring the oil to the correct level.
3. Replace the plug sealing ring if necessary and screw in the plug.
Start the machine and carry out a test 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
Drain the oil completely from the following components:

■ Oil separator tank
■ Oil cooler
■ Airend
■ Oil tank (only option K2)
■ 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 is stowed beneath the oil separator tank.
WARNING
There is risk of burns from hot components and oil.

78 BSD 9_5708 08 USE
10 Maintenance
Fig. 32 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 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.
Draining the oil from the separator tank
1. Have an oil receptacle ready.

3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .

9_5708 08 USE BSD 79
10 Maintenance
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. 33 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 psig.

80 BSD 9_5708 08 USE
10 Maintenance
Draining the oil from the airend
Fig. 34 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

2. With the shut-off valve closed, insert the male hose fitting 6 (Fig. 32) into the hose coupling 2 .
4. Open shut-off valves 3 and 7 (Fig. 32)
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.

9_5708 08 USE BSD 81
10 Maintenance
Option K2 Draining the oil from the tank
Fig. 35 Changing the cooling oil, oil tank

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

4. Open the shut-off valves 3 and 7 and allow the oil to drain completely.
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.
Precondition The power supply isolating device is switched off,

The machine is fully vented, the pressure gauge on the oil separator tank reads 0 psig.

2. Open the external heat recovery system and allow the oil to drain completely.
3. Close the external heat recovery system.
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.

82 BSD 9_5708 08 USE
10 Maintenance
10.17 Changing the Oil Filter
Fig. 36 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. 32) in the hose coupling 1 .
4. Open the shut-off valves 3 and 7 (Fig. 32) and allow the oil to drain completely.
Filling with cooling oil
1. Open the filler plug 4 (Fig. 32) slowly.

2. Fill with cooling oil.
3. Check the filler plug and ring seal for damage and screw the plug back in again.
Start the machine and carry out a trial run
2. Open the user's shut-off valve between the machine and the air distribution network.
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.
10.17 Changing the Oil Filter


Cooling oil container

The machine is fully vented, the pressure gauge reads 0 psig.

9_5708 08 USE BSD 83
10 Maintenance
10.18 Changing the Oil Separator Cartridge
WARNING
There is risk of burns from hot components and oil.
Fig. 37 Changing the oil filter

1 Oil filter
2 Direction to unscrew
Changing the oil filter
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.
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.

84 BSD 9_5708 08 USE
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 rag

The machine is fully vented, the pressure gauge reads 0 psig.
Fig. 38 Changing the Oil Separator Cartridge

14 Cover 19 Nut (self locking)
15 Dirt trap 20 Fitting
16 Air pipe 21 Gasket
17 Retaining screw 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 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 .

9_5708 08 USE BSD 85
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.
4. Stop the machine after 10 minutes and visually check for leaks.

86 BSD 9_5708 08 USE
10 Maintenance
10.19 Document maintenance and service work.
10.19 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. 51 Logged maintenance tasks

9_5708 08 USE BSD 87
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 inquiry and order for spares.
11.2 Ordering consumable parts and operating fluids/materials

KAESER consumable parts and operating materials are original Kaeser products. 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 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
Name Quantity Number

Air filter element 1 1250
Filter mat (control cabinet) 2 1100
Filter mat (option K3) 1 1050
Oil filter 1 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Bearing grease [g] 100 9.0915.0
400 6.3234.0
Tab. 52 Consumable parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ authorized 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,

88 BSD 9_5708 08 USE
11.4 Service Addresses
■ the security of genuine KAESER spare parts,

■ increased legal certainty as all regulations are kept to.
➤ Why not sign a KAESER AIR SERVICE maintenance agreement!
Result Your advantage:

lower costs and higher compressed air availability.
11.4 Service Addresses

Addresses of KAESER representatives 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 representative.

9_5708 08 USE BSD 89

90 BSD 9_5708 08 USE

9_5708 08 USE BSD 91

92 BSD 9_5708 08 USE

9_5708 08 USE BSD 93
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 power supply disconnecting device,
the disconnect device is locked in the off position,
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 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
Precondition The machine is decommissioned.

Machine is dry and cooled down.
1. Place desiccant 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 oil separator tank.
Frozen moisture can damage components, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and re-commissioning.

94 BSD 9_5708 08 USE
12.4 Transporting
CAUTION
Machine damage from moisture and frost.
➤ Prevent ingress of moisture and condensation.
➤ Maintain >32 °F storage temperature.
➤ Store the machine in a dry, frost-proof room.
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.
➤ Make sure the danger zone is clear.
12.4.2 Transporting with a forklift

Precondition The whole machine must be over the forks.
Fig. 39 Transporting with a forklift
➤ Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transporting with a crane

A suitable lifting cradle ensures correct transportation.
The lifting slings must be fully under the machine.
The slings must not press on the side of the machine.
Examples of unsuitable fixing points:

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

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

9_5708 08 USE BSD 95
12.5 Disposal
Fig. 40 Transporting with a crane

1 Lifting cradle
2 Slings
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.
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.
➤ Parts contaminated with cooling oil must be disposed of in accordance with local environ‐
ment protection regulations.
Compressors with refrigeration dryers
The sealed refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by authorized personnel.

96 BSD 9_5708 08 USE
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13 Annex

9_5708 08 USE BSD 97
13 Annex

98 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 99
13 Annex

100 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 101
13 Annex

102 BSD 9_5708 08 USE
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_5708 08 USE BSD 103
13 Annex

104 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 105
13 Annex

106 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 107
13 Annex

108 BSD 9_5708 08 USE
13 Annex
13.3 Dimensional Drawing

9_5708 08 USE BSD 109
13 Annex

110 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 111
13 Annex

112 BSD 9_5708 08 USE
13 Annex
13.4 Electrical Diagram

9_5708 08 USE BSD 113
13 Annex

114 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 115
13 Annex

116 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 117
13 Annex

118 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 119
13 Annex

120 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 121
13 Annex

122 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 123
13 Annex

124 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 125
13 Annex

126 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 127
13 Annex

128 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 129
13 Annex

130 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 131
13 Annex

132 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 133
13 Annex

134 BSD 9_5708 08 USE
13 Annex

9_5708 08 USE BSD 135
13 Annex

136 BSD 9_5708 08 USE

BSD 40

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BSD 40

Uploaded by

Copyright:

Available Formats

Service Manual

1 Regarding this Document

Service Manual Screw Compressor

4 Design and Function

Service Manual Screw Compressor

9.3 Warning messages (yellow LED lights) ............................................................................ 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 ..................................................................................... 1

Service Manual Screw Compressor

Service Manual Screw Compressor

1 Regarding this Document

1.2 Further Documents

Missing documents can be requested from KAESER.

1.4 Symbols and Identification

➤ Always read and comply with warning instructions.

Signal word Meaning Consequences of non-observance

Service Manual Screw Compressor

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 data from the nameplate here as reference:

Option Option code Available?

Service Manual Screw Compressor

Option Option code Available?

BSD 40 BSD 50 BSD 60

Tab. 4 Machine weight

2.5 Ambient Conditions

Tab. 6 Ambient Conditions

Service Manual Screw Compressor

Fig. 1 Maximum relative humidity

BSD 40 BSD 50 BSD 60

Safety relief valve blow-off setting [psig]:

Maximum working pres‐ BSD 40 BSD 50 BSD 60

Tab. 8 Safety relief valve setting

Service Manual Screw Compressor

Maximum working pres‐ BSD 40 BSD 50 BSD 60

2.9 Cooling Oil Recommendation

2.9.1 Basic Information

2.9.2 KAESER Lubricants

Service Manual Screw Compressor

Specialty KAESER LUBRICANTS:

2.10 Cooling oil charge

BSD 40 BSD 50 BSD 60

Tab. 10 Cooling oil charge (Option K1)

Option K2 Water cooling

BSD 40 BSD 50 BSD 60

Tab. 11 Cooling oil charge (Option K2)

Service Manual Screw Compressor

Option W1/W2/W3 Heat recovery

Tab. 12 Cooling oil charge (Option W1)

Option W2 BSD 40 BSD 50 BSD 60

Tab. 13 Cooling oil charge (Option W2)

Option W3 BSD 40 BSD 50 BSD 60

Tab. 14 Cooling oil charge (Option W3)

2.11 Motors and Power

Tab. 15 Drive motor