Asd 60 T

Operating Manual
Screw Compressor
ASD T SIGMA CONTROL 2

901713 05 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SASD 2.15 en SBA-SCHRAUBEN-T-SC
/KKW/SSC 2.05
20160614 130657
Contents
1 Regarding this document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Mass ................................................................................................................................. 5
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 6
2.8 Flow rate (constant delivery volume relative to intake conditions) ................................... 7
2.9 Cooling oil recommendation ............................................................................................. 8
2.10 Cooling oil charge ............................................................................................................ 9
2.11 Motors and power ............................................................................................................ 10
2.11.1 Compressor motor .............................................................................................. 10
2.11.2 Fan motor ........................................................................................................... 11
2.12 Noise emission [dB(A)] ..................................................................................................... 11
2.13 Electrical connection ........................................................................................................ 12
2.14 Power supply specifications ............................................................................................. 12
2.14.1 Mains frequency: 50 Hz ...................................................................................... 13
2.14.2 Mains frequency: 60 Hz ...................................................................................... 13
2.15 Heat recovery ................................................................................................................... 14
2.16 Refrigeration dryer ........................................................................................................... 17
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 18
3.2 Specified use .................................................................................................................... 18
3.3 Improper use .................................................................................................................... 18
3.4 User's responsibilities ....................................................................................................... 18
3.4.1 Observe statutory and universally accepted regulations .................................... 18
3.4.2 Determining personnel ........................................................................................ 19
3.4.3 Keeping to Inspection Schedules and Accident Prevention Regulations ........... 19
3.5 Dangers ............................................................................................................................ 20
3.5.1 Safely dealing with sources of danger ................................................................ 20
3.5.2 Safe machine operation ...................................................................................... 22
3.5.3 Organisational Measures .................................................................................... 24
3.5.4 Danger Areas ...................................................................................................... 24
3.6 Safety devices .................................................................................................................. 25
3.7 Working life of safety functions ........................................................................................ 25
3.8 Safety signs ...................................................................................................................... 26
3.9 Emergency situations ....................................................................................................... 27
3.9.1 Correct fire fighting ............................................................................................. 27
3.9.2 Treating injuries from handling cooling oil .......................................................... 27
3.9.3 Injury from Handling Refrigerant ......................................................................... 28
3.10 Warranty ........................................................................................................................... 28
3.11 Environment protection .................................................................................................... 29
4 Design and Function
4.1 Enclosure ......................................................................................................................... 30
Operating Manual Screw Compressor

901713 05 E ASD T SIGMA CONTROL 2 i
Contents
4.2 Machine function .............................................................................................................. 30

4.2.1 Refrigeration dryer .............................................................................................. 32
4.2.2 Safety devices .................................................................................................... 32
4.2.3 Floating relay contacts ........................................................................................ 32
4.3 Operating panel SIGMA CONTROL 2 ............................................................................ 33
4.4 Operating modes and control modes ............................................................................... 35
4.4.1 Machine operating modes .................................................................................. 35
4.4.2 Control modes .................................................................................................... 36
4.5 Refrigeration Dryer Control Modes .................................................................................. 38
4.6 Options ............................................................................................................................. 38
4.6.1 Machine mountings ............................................................................................. 38
4.6.2 Cooling air filter mat ............................................................................................ 38
4.6.3 Heat recovery ..................................................................................................... 39
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 40
5.2 Installation conditions ....................................................................................................... 40
5.2.1 Determining location and clearances .................................................................. 40
5.2.2 Ensuring the machine room ventilation ............................................................... 41
5.2.3 Exhaust duct design ........................................................................................... 42
5.3 Operating the machine in a compressed air network ....................................................... 42
6 Installation
6.1 Ensuring safety ................................................................................................................ 43
6.2 Reporting Transport Damage ........................................................................................... 44
6.3 Connecting the machine with the compressed air network .............................................. 44
6.4 Connecting the condensate drain .................................................................................... 44
6.5 Connecting the external pressure transducer .................................................................. 46
6.6 Refrigeration dryer: Connecting the transformer according to the mains supply. ............ 47
6.7 Connecting the machine with the power supply ............................................................... 47
6.8 Options ............................................................................................................................. 48
6.8.1 Anchoring the machine ....................................................................................... 48
6.8.2 Connecting the heat recovery system ................................................................ 48
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 50
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 51
7.3 Checking installation and operating conditions ................................................................ 51
7.4 Setting the overload protection cut-out ............................................................................ 52
7.5 Setting the motor overload protection switch ................................................................... 52
7.6 Pouring cooling oil into the airend .................................................................................... 52
7.7 Activating and deactivating the MODULATING control .................................................... 54
7.8 Starting the machine for the first time .............................................................................. 54
7.9 Setting the network setpoint pressure .............................................................................. 55
7.10 Setting the display language ............................................................................................ 55
8 Operation
8.1 Switching on and off ......................................................................................................... 57
8.1.1 Switching on ....................................................................................................... 57
8.1.2 Switching off ....................................................................................................... 57
8.2 Switching off in an emergency and switching on again .................................................... 58
8.3 Using the remote control for switching on and off ............................................................ 58
8.4 Using the timer for switching on and off ........................................................................... 59
8.5 Interpreting operation messages ...................................................................................... 60
8.6 Acknowledging alarm and warning messages ................................................................. 60

ii ASD T SIGMA CONTROL 2 901713 05 E
Contents
9 Fault Recognition and Rectification

9.1 Basic instructions ............................................................................................................. 62
9.2 Other faults ....................................................................................................................... 62
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 64
10.2 Following the maintenance plan ....................................................................................... 65
10.2.1 Logging maintenance work ................................................................................. 65
10.2.2 Resetting maintenance interval counters ............................................................ 65
10.2.3 Regular maintenance tasks ................................................................................ 65
10.2.4 Cooling oil Change interval ................................................................................. 67
10.2.5 Regular service tasks ......................................................................................... 67
10.3 Control cabinet: Clean or renew the filter mat .................................................................. 68
10.4 Cooler maintenance ......................................................................................................... 69
10.5 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 70
10.6 Maintaining the heat recovery system .............................................................................. 71
10.7 Change the air filter .......................................................................................................... 71
10.8 Motor maintenance .......................................................................................................... 72
10.9 Checking the Coupling ..................................................................................................... 72
10.10 Testing the pressure relief valve ...................................................................................... 73
10.11 Check the safety shut-down due to excessive airend discharge temperature. ................ 74
10.12 Testing the EMERGENCY STOP device ......................................................................... 75
10.13 Checking the cooling oil level ........................................................................................... 75
10.14 Venting the machine (de-pressurising) ............................................................................ 76
10.15 Replenishing the cooling oil ............................................................................................. 78
10.15.1 Venting the machine (de-pressurising) ............................................................... 78
10.15.2 Topping up with cooling oil and trial run ............................................................. 79
10.16 Changing the cooling oil ................................................................................................... 80
10.17 Changing the oil filter cartridge ........................................................................................ 85
10.18 Changing the oil separator cartridge ................................................................................ 86
10.19 Cleaning the refrigerant condenser .................................................................................. 88
10.20 Maintaining the condensate drain .................................................................................... 88
10.20.1 Condensate drain check ..................................................................................... 88
10.20.2 Changing the service unit ................................................................................... 89
10.21 Documenting maintenance and service work .................................................................. 91
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 92
11.2 Ordering consumable parts and operating fluids/materials .............................................. 92
11.3 KAESER AIR SERVICE .................................................................................................. 92
11.4 Service Addresses ........................................................................................................... 93
11.5 Replacement parts for service and repair ........................................................................ 93
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 100
12.2 Packing ............................................................................................................................ 100
12.3 Storage ............................................................................................................................. 100
12.4 Transport .......................................................................................................................... 101
12.4.1 Safety .................................................................................................................. 101
12.4.2 Transport with a forklift truck ............................................................................... 101
12.4.3 Transport with a crane ........................................................................................ 101
12.5 Disposal ........................................................................................................................... 102
12.5.1 Dispose of the battery in accordance with local environmental regulations. ...... 103
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 104

901713 05 E ASD T SIGMA CONTROL 2 iii
Contents
13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control .................. 110
13.3 Dimensional drawing ........................................................................................................ 116
13.4 Electrical Diagram ............................................................................................................ 119

iv ASD T SIGMA CONTROL 2 901713 05 E
List of Illustrations
Fig. 1 Maximum relative humidity of inlet air ........................................................................................ 6

Fig. 2 Location of safety signs .............................................................................................................. 26
Fig. 3 Enclosure overview .................................................................................................................... 30
Fig. 4 Machine overview ....................................................................................................................... 31
Fig. 5 Refrigeration dryer ...................................................................................................................... 32
Fig. 6 Keys - overview .......................................................................................................................... 33
Fig. 7 Indicators – overview .................................................................................................................. 34
Fig. 8 RFID reader ................................................................................................................................ 35
Fig. 9 Machine mountings .................................................................................................................... 38
Fig. 10 Cooling air filter mat (option K3) ................................................................................................. 39
Fig. 11 Function of the heat recovery ..................................................................................................... 39
Fig. 12 Recommended machine placement and dimensions [mm] ........................................................ 41
Fig. 13 Compressed pipework ................................................................................................................ 44
Fig. 14 Connecting the condensate drain ............................................................................................... 46
Fig. 15 Connecting the heat recovery system ........................................................................................ 48
Fig. 16 Inlet valve oil filling port .............................................................................................................. 53
Fig. 17 Coupling ..................................................................................................................................... 53
Fig. 18 MODULATING control: Setting the shut-off valve ...................................................................... 54
Fig. 19 Switching on and off ................................................................................................................... 57
Fig. 20 Switching off in an emergency ................................................................................................... 58
Fig. 21 Using the remote control for switching on and off ...................................................................... 59
Fig. 22 Using the timer for switching on and off ..................................................................................... 60
Fig. 23 Acknowledging messages .......................................................................................................... 61
Fig. 24 Switching cabinet ventilation ...................................................................................................... 68
Fig. 25 Cleaning the cooler .................................................................................................................... 69
Fig. 26 Cooling air filter mat ................................................................................................................... 70
Fig. 27 Air filter maintenance .................................................................................................................. 71
Fig. 28 Checking the coupling ............................................................................................................... 73
Fig. 29 Testing the EMERGENCY STOP device ................................................................................... 75
Fig. 30 Checking the cooling oil level ..................................................................................................... 76
Fig. 31 Venting the machine ................................................................................................................... 77
Fig. 32 Replenishing the cooling oil ........................................................................................................ 78
Fig. 33 Changing the cooling oil, oil separator tank ............................................................................... 81
Fig. 34 Changing the cooling oil, oil cooler ............................................................................................. 82
Fig. 35 Changing the cooling oil, airend ................................................................................................. 83
Fig. 36 Changing the cooling oil, heat recovery system ......................................................................... 84
Fig. 37 Changing the oil filter .................................................................................................................. 85
Fig. 38 Changing the oil separator cartridge .......................................................................................... 87
Fig. 39 Refrigeration dryer ...................................................................................................................... 88
Fig. 40 Condensate drain check ............................................................................................................. 89
Fig. 41 Changing the service unit ........................................................................................................... 90
Fig. 42 Transporting with a forklift truck ................................................................................................. 101
Fig. 43 Transporting with a crane ........................................................................................................... 102
Fig. 44 Battery labelling .......................................................................................................................... 103

901713 05 E ASD T SIGMA CONTROL 2 v
List of Illustrations

vi ASD T SIGMA CONTROL 2 901713 05 E
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Mass ........................................................................................................................................... 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 8 Overview Ventilation (50Hz) ....................................................................................................... 6
Tab. 9 Overview Ventilation (60Hz) ....................................................................................................... 6
Tab. 10 Pressure relief valve activating pressure (50Hz) ........................................................................ 7
Tab. 11 Pressure relief valve activating pressure (60Hz) ........................................................................ 7
Tab. 12 Flow rate (50Hz) ......................................................................................................................... 7
Tab. 13 Flow rate (60 Hz) ........................................................................................................................ 7
Tab. 14 Cooling oil recommendation ....................................................................................................... 8
Tab. 15 Cooling oil recommendation (food processing) .......................................................................... 8
Tab. 16 Cooling oil recommendation (machines for snow cannons) ....................................................... 9
Tab. 17 Cooling oil charge ...................................................................................................................... 10
Tab. 18 Cooling oil charge (option W2) ................................................................................................... 10
Tab. 19 Cooling oil charge (option W3) ................................................................................................... 10
Tab. 20 Compressor motor (50Hz) .......................................................................................................... 10
Tab. 21 Compressor motor (60Hz) .......................................................................................................... 11
Tab. 22 Fan motor (50Hz) ....................................................................................................................... 11
Tab. 23 Fan motor (60Hz) ....................................................................................................................... 11
Tab. 24 Noise emission [dB(A)] ............................................................................................................... 11
Tab. 25 Supply details 200V / 3 / 50Hz ................................................................................................... 13
Tab. 32 Heat recovery: Individual design data ........................................................................................ 14
Tab. 33 Specification: Heat exchanger (Option W2/W3) ......................................................................... 15
Tab. 34 Quality of the heat receiving medium ......................................................................................... 15
Tab. 35 Heat capacity (Option W2/W3) ................................................................................................... 16
Tab. 36 Flow rate / pressure drop (option W2) ........................................................................................ 16
Tab. 37 Flow rate / pressure drop (option W3) ........................................................................................ 16
Tab. 38 Refrigeration dryer: Model .......................................................................................................... 17
Tab. 39 Refrigeration dryer: Compressed air system .............................................................................. 17
Tab. 40 Refrigeration dryer: Refrigerant system ..................................................................................... 17
Tab. 41 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 20
Tab. 42 Danger Areas ............................................................................................................................. 25
Tab. 43 Category and Performance Level ............................................................................................... 25
Tab. 44 Safety signs ................................................................................................................................ 26
Tab. 45 Keys ........................................................................................................................................... 33
Tab. 46 Indicators .................................................................................................................................... 34
Tab. 47 RFID reader ................................................................................................................................ 35
Tab. 48 Energy-saving control modes ..................................................................................................... 37
Tab. 49 Refrigeration dryer control modes .............................................................................................. 38
Tab. 50 Condensate line ......................................................................................................................... 45
Tab. 51 Condensate collecting line ......................................................................................................... 45
Tab. 52 Condensate collecting line: Line cross-section .......................................................................... 45
Tab. 53 Re-commissioning after storage ................................................................................................. 51
Tab. 54 Installation conditions checklist .................................................................................................. 51

901713 05 E ASD T SIGMA CONTROL 2 vii
List of Tables
Tab. 55 MODULATING control: Setting the shut-off valve ...................................................................... 54

Tab. 56 Machine identification ................................................................................................................. 59
Tab. 57 Remote control identification ...................................................................................................... 59
Tab. 58 Machine identification ................................................................................................................. 60
Tab. 59 Other faults and remedies .......................................................................................................... 62
Tab. 60 Advise others that the machine is being serviced. ..................................................................... 64
Tab. 61 Regular maintenance tasks ........................................................................................................ 66
Tab. 62 Cooling oil Change intervals ....................................................................................................... 67
Tab. 63 Regular service tasks ................................................................................................................. 67
Tab. 64 Logged maintenance tasks ........................................................................................................ 91
Tab. 65 Consumable parts ...................................................................................................................... 92

viii ASD T SIGMA CONTROL 2 901713 05 E
1.1 Using this document

1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents

Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Declaration of Conformity in accordance with the applicable directive
■ Operating manual for SIGMA CONTROL 2
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent threat of danger Will result in death or severe injury
WARNING Warns of possible danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.

901713 05 E ASD T SIGMA CONTROL 2 1
Example:
DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols

This symbol identifies particularly important information.

2 ASD T SIGMA CONTROL 2 901713 05 E
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 symbol denotes lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with screw-in machine feet). Option codes used in this
operating manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.

2.1 Nameplate
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine:

■ above the cooler, or
■ on the rear of the machine.
➤ Enter here the nameplate data as a reference:
Feature Value
Rotary screw compressor
Material no.
Serial no.
Year of manufacture
Rated power
Rated motor speed
Maximum working pressure
Ambient temperature
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options. The options for this machine are shown near the
nameplate.
➤ Enter options here as a reference.
Option Option code Available?

MODULATING control C1
SIGMA CONTROL 2 C3 ✓
IT-three-phase network C35 —
Bolt-down machine feet H1
Air-cooling K1 ✓
Cooling-air filter mat K3
Transformer power supply for refrigeration dryer T2
Heat recovery ΔT=25 K W2
Heat recovery ΔT=55 K W3
available: ✓
not available: —
Tab. 4 Options

2.3 Mass
2.3 Mass
The values shown are maximum values. Actual mass of individual machines are dependent on
equipment fitted.
ASD 35 ASD 40 ASD 50 ASD 60

Mass [kg] 705 750 790 845
Tab. 5 Mass
2.4 Temperature
Minimum cut-in tempera‐ 3 3 3 3
ture [°C]
Typical airend discharge 65 – 100 65 – 100 65 – 100 65 – 100
temperature during oper‐
ation* [°C]
Maximum airend dis‐ 110 110 110 110
charge temperature (au‐
tomatic safety shut-down)
[°C]
* The machine continuously changes the airend discharge temperature corresponding to the am‐
bient temperature.
Tab. 6 Temperature
2.5 Ambient conditions

Maximum eleva‐ 1000 1000 1000 1000
tion AMSL* [m]
Permissible ambient tem‐ 3 – 45 3 – 45 3 – 45 3 – 45
perature [°C]
Cooling air tempera‐ 3 – 45 3 – 45 3 – 45 3 – 45
ture [°C]
Inlet air temperature [°C] 3 – 45 3 – 45 3 – 45 3 – 45
* Higher elevation permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions

2.6 Ventilation
Fig. 1 Maximum relative humidity of inlet air

T Inlet air temperature [°C]
H Maximum relative humidity of inlet air [%]
2.6 Ventilation
Values given are minimum guidelines.
Ventilation at 50 Hz mains frequency:

Inlet aperture Z see fig‐ 0.6 0.7 0.8 0.9
ure 12 [m2]
Extractor for forced venti‐ 9000 10000 12000 14000
lation:
Flow rate [m3/h] at
100 Pa
Tab. 8 Overview Ventilation (50Hz)
Ventilation at 60 Hz mains frequency:

Inlet aperture Z see fig‐ 0.6 0.7 0.8 0.9
ure 12 [m2]
Extractor for forced venti‐ 9000 10000 12000 14000
lation:
Flow rate [m3/h] at
100 Pa
Tab. 9 Overview Ventilation (60Hz)
2.7 Pressure
Maximum working pressure: (see nameplate)

2.8 Flow rate (constant delivery volume relative to intake conditions)
Pressure relief valve activating pressure at 50 Hz [bar]:
Maximum working over‐ ASD 35 ASD 40 ASD 50 ASD 60

pressure [bar]
8.5 10 10 10 10
12.0 14 14 14 14
15.0 —* 16 * 16 * 16 *
* China: 15.9
Tab. 10 Pressure relief valve activating pressure (50Hz)
Pressure relief valve activating pressure at 60 Hz [bar]:
Maximum working over‐ ASD 35 ASD 40 ASD 50 ASD 60

pressure [bar]
8.5 10 10 10 10
12.0 — 14 14 14
15.0 — — 16 16
Tab. 11 Pressure relief valve activating pressure (60Hz)
2.8 Flow rate (constant delivery volume relative to intake conditions)

Flow rate [m3/min] at 50 Hz mains frequency:
Max. working pres‐ ASD 35 ASD 40 ASD 50 ASD 60

sure [bar]
8.5 3.15 3.90 4.55 5.50
12.0 2.60 3.10 3.80 4.42
15.0 — 2.50 2.95 3.55
Flow rate as per ISO 1217:2009. Annex C
Tab. 12 Flow rate (50Hz)
Flow rate [m3/min] at 60 Hz mains frequency:
Max. working pres‐ ASD 35 ASD 40 ASD 50 ASD 60

sure [bar]
8.5 3.17 3.74 4.60 5.40
12.0 — 3.12 3.60 4.50
15.0 — — 3.00 3.48
Flow rate as per ISO 1217:2009. Annex C
Tab. 13 Flow rate (60 Hz)

2.9 Cooling oil recommendation
2.9 Cooling oil recommendation

A sticker showing the type of oil used is located near the oil separator tank filler.
Information on ordering cooling oil is found in chapter 11.
Cooling oils for general applications
SIGMA FLUID
MOL S-460 S-570
Description Mineral oil Silicone-free Synthetic oil
synthetic oil
Application Standard oil for all appli‐ Standard oil for all applica‐ Special oil for ambient
cations except in con‐ tions except in connection conditions with high tem‐
nection with foodstuffs. with foodstuffs. peratures and humidity.
Particularly suitable for Particularly suitable for ma‐ Standard oil for all appli‐
machines with a low du‐ chines with a high duty cycle. cations except in connec‐
ty cycle. Not suitable for East- / South- tion with foodstuffs.
East-Asian countries. Particularly suitable for
machines with a high duty
cycle.
Approval — — —
Viscosity at 44 mm /s
2
45 mm /s2
52.8 mm2/s
40 °C (DIN 51562–1) (D 445; ASTM test) (D 445; ASTM test)
Viscosity at 6.8 mm2/s 7.2 mm2/s 8.0 mm2/s
100 °C (DIN 51562-1) (D 445; ASTM test) (D 445; ASTM test)
Flash point 220 °C 238 °C 258 °C
(ISO 2592) (D 92; ASTM test) (D 92; ASTM test)
Density at — 864 kg/m3 0.869 kg/l
15 °C (ISO 12185) (D 1298; ASTM test)
Pour point –33 C –46 ℃ –54 ℃
(ISO 3016) (D 97; ASTM test) (D 97; ASTM test)
Demulsibility — 40/40/0/10 min 15 min
at 54 °C (D 1401; ASTM test) (D 1401; ASTM test)
Tab. 14 Cooling oil recommendation
Cooling oils for applications in food processing
SIGMA FLUID
FG-460 FG-680
Description Synthetic oil Synthetic oil
Application Specifically for machines in applica‐ Special oil for ambient conditions with
tions where the compressed air high temperatures and humidity.
may come into contact with food‐ Specifically for machines in applications
stuff. where the compressed air may come into
contact with foodstuff.

2.10 Cooling oil charge
SIGMA FLUID
FG-460 FG-680
Approval USDA H-1, NSF USDA H-1, NSF
Approved for the manufacture of Approved for the manufacture of food
food packaging, meat and poultry packaging, meat and poultry processing
processing and other food process‐ and other food processing applications.
ing applications.
Viscosity at 40 °C 50.7 mm2/s 70.0 mm2/s
(D 445; ASTM test) (D 445; ASTM test)
Viscosity at 8.2 mm2/s 10.4 mm2/s
100 °C (D 445; ASTM test) (D 445; ASTM test)
Flash point 245 °C 245 °C
(D 92; ASTM test) (D 92; ASTM test)
Density at 15 °C — —
Pour point — —
Demulsibility at — —
54 °C
Tab. 15 Cooling oil recommendation (food processing)
Cooling oils for the operation with snow cannons
SIGMA FLUID
PANOLIN HLP SYNTH 46
Description Saturated synthetic ester with additives (mineral oil free).
Easily biologically degradable as per OECD criteria.
Application Specifically designed for machines intended for the operation with snow
cannons.
Approval —
Viscosity at 40 °C 47 mm2/s
Viscosity at 8.1 mm2/s
100 °C
Flash point >210 °C
Density at 15 °C 0.92 g/ml
Pour point –35 °C
Demulsibility at 54 °C —
Tab. 16 Cooling oil recommendation (machines for snow cannons)
2.10 Cooling oil charge

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

2.11 Motors and power
Air-cooling

Fluid volume [l]
1) 16 16 16 16
Topping up volume [l] 2 2 2 2
(minimum–maximum)
1)
Plus the oil volume of the heat recovery system.
Tab. 17 Cooling oil charge
Option W2/W3 Heat recovery
Option W2 ASD 35 ASD 40 ASD 50 ASD 60

Additional charge vol‐ 2.2 2.2 / 4.21) 2.22) / 4.2 4.2
ume [l]
1)
8,5 bar
2)
15 bar
Tab. 18 Cooling oil charge (option W2)
Option W3 ASD 35 ASD 40 ASD 50 ASD 60

Additional charge vol‐ 2.2 2.2 2.2 2.6
ume [l]
Tab. 19 Cooling oil charge (option W3)
2.11 Motors and power

2.11.1 Compressor motor
Mains frequency: 50 Hz

Rated power [kW] 18.5 22.0 25.0 30.0
Rated speed [min ] −1 2960 2960 2970 2965
Enclosure protection IP 55 IP 55 IP 55 IP 55
Motor bearing re-greas‐ 6000 6000 6000 6000
ing interval [h]
Grease requirement*,
each bearing [g]
h = operating hours
* Copy the data from the motor nameplate into the table.
Tab. 20 Compressor motor (50Hz)

2.12 Noise emission [dB(A)]

Rated power [kW] 18.5 22.0 30.0 30.0
Rated speed [min−1] 3565 3560 3570 3570
Motor bearing re-greas‐ 6000 6000 6000 6000
ing interval [h]
Grease requirement*,
each bearing [g]
h = operating hours
* Copy the data from the motor nameplate into the table.
Tab. 21 Compressor motor (60Hz)
2.11.2 Option K1
Fan motor

Rated power [kW] 0.55 0.55 0.55 0.55
Rated speed [min−1] 940 940 940 940
h = operating hours
Tab. 22 Fan motor (50Hz)

Rated power [kW] 0.55 0.55 0.55 0.55
Rated speed [min−1] 1150 1150 1150 1150
h = operating hours
Tab. 23 Fan motor (60Hz)
2.12 Noise emission [dB(A)]

Mains frequency ASD 35 ASD 40 ASD 50 ASD 60
50 Hz 65 66 66 69
60 Hz 66 67 67 69
Noise pressure level in operation at maximum air delivery as per ISO 2151 and the basic standard
ISO 9614-2, uncertainty: ±3 dB(A)
Tab. 24 Noise emission [dB(A)]

2.13 Electrical connection
2.13 Electrical connection

The machine is designed in accordance with the conditions for an electrical power supply specified
in EN 60204-1 (IEC 60204-1) section 4.3.
If no other conditions are specified by the operator, the thresholds described in this standard must
be adhered to.
It is recommended that the user and the supplier reach an agreement on the basis of EN 60204-1,
Annex B.
For electrical connection of the machine, a symmetric three-phase supply is necessary.
In a symmetrical three-phase supply the phase angles and voltages are all the same.
This machine is designed for the operation in an industrial environment with proprietary supply net‐
work separated from the public supply by a transformer or generator.
Incoming line within the switching cabinet to be as short as possible.
If external sensors or communications lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC connections into the switching cabinet.
This machine may only be supplied from an earthed TN or TT three-phase supply in which
the neutral point is earthed.
The connection to an IT three-phase supply or a three-phase supply with one earthed phase
is not permitted.
Further information The wiring diagram in chapter 13.4 contains further details of the power supply connection.
2.14 Power supply specifications

Supply diameters and fusing (class gG) are selected according to DIN VDE 0100 part 430
(IEC 60364-4-43) and DIN VDE 0298-4:2013-06 if the following conditions are met:
■ multi-core copper conductors at an operating temperature up to 70 °C
■ Cable length <50 m
■ For an ambient temperature of 30 °C
■ Wiring type C, without cable contact
■ Current carrying capacity: Table 3 Column 11
(European Harmonisation Directive HD 60364-5-522011)
■ Bundled cables: Table 21
─ Single layer on wall or floor
─ Spacing ≥ outside diameter
➤ For other application conditions, check and determine the supply diameters according to
DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider.
Other conditions would include, for example:

■ Higher ambient temperature
■ Other cable installation method
■ Other bundled cables
■ Cable length >50 m
Further information The wiring diagram in chapter 13.4 contains further details of the electrical connection data.

2.14 Power supply specifications
2.14.1 Mains frequency: 50 Hz

Rated voltage: 200V / 3 / 50Hz

Backup fuse [A] 100 100 125 160
Supply cable [mm2] 4x35 4x35 4x50 4x70
Current drawn [A] 79 91 107 130
Tab. 25 Supply details 200V / 3 / 50Hz

Backup fuse [A] 80 100 125 125

Backup fuse [A] 50 50 63 80
2.14.2 Mains frequency: 60 Hz


Backup fuse [A] 80 100 125 125


2.15 Heat recovery


2.15 Option W2/W3

Heat recovery
There are typical layout examples. Conditions for each individual installation could vary from these
guidelines.
The reasons may be (examples):

■ Fluctuating condensate flow
■ Working pressure
■ Inlet conditions
■ Ambient conditions
■ Machine settings
Water is generally the heat-receiving medium. The water must meet the quality specified below in
order not to damage the heat exchanger.
The specified flow rate relates to the maximum available heat capacity.
➤ If required, enter your individual values in the prepared table.
➤ If the design data differ, request that the settings in SIGMA CONTROL 2 are checked by
the KAESER SERVICE.
➤ Consult KAESER SERVICE if you wish to use a different heat-receiving medium.
The primary side of the heat exchanger is connected to the cooling oil circuit of the machine.
The specifications refer to the secondary side of the heat exchanger.
Individual design data
My value
Heating from [°C]
Heating to [°C]

2.15 Heat recovery
My value
Temperature difference
(ΔT) [K]
Maximum available heat
output [kW]
(relative to ___ bar work‐
ing pressure)
Flow rate [m3/h]
Pressure drop [bar]
Tab. 32 Heat recovery: Individual design data
Component sprecification:
Feature Value
Material 1.4401
Braze Copper (Cu)
Max. working pres‐ 10
sure [bar]
Minimum permissible in‐ 5
let temperature [°C]
Max. permissible inlet 45
temperature* [°C]
Continuously possible 70
outlet temperature [°C]
Maximum permissible 100
outlet temperature [°C]
(Component limit value)
Maximum permissible 8.7
flow rate [m3/h]
Unsuitable cooling media Salt water
Consult KAESER on the suitability of water.
* Consult KAESER about higher values.
Tab. 33 Specification: Heat exchanger (Option W2/W3)
Quality of the heat receiving medium
Characteristics/content Value
pH value 7.5 – 9.0
Hardness [°dH] 0 – 20
Carbonate hardness* [°dH] <20
Chlorides (Cl) [mg/l] <100
Iron (Fe), dissolved [mg/l] <0.5
Sulphate (SO4) [mg/l] <300
* CFU: colony-forming units

2.15 Heat recovery
Characteristics/content Value
HCO3/SO4 ratio >1
Electrical conductivity [µS/cm] 10 – 800
Ammonia (NH4 +) [mg/l] <1
Manganese (Mn), dissolved [mg/l] <0.1
Glycol [%] 20–40
Solids (particle size) [mm] <0.1
Bacterial count [CFU*/ml] 10,000
Suspended solids [ppm] <20
(portion of undissolved matter)
* CFU: colony-forming units
Tab. 34 Quality of the heat receiving medium
Heat capacity
Maximum heat capacity ASD 35 ASD 40 ASD 50 ASD 60

available
[kW] 15.2 18.1 21.6 26.6
[MJ/h] 55 65 78 96
[kcal/h] 13070 15570 18580 22880
Tab. 35 Heat capacity (Option W2/W3)
Option W2 Flow rate for heating from 45 °C to 70 °C (equates to ΔT=25K)

Flow rate [m3/h] 0.52 0.62 0.74 0.92
Pressure drop [bar] 0.15 0.15 0.20 0.20
Tab. 36 Flow rate / pressure drop (option W2)
Option W3 Flow rate for heating from 15 °C to 70 °C (equates to ΔT=55K)

Flow rate [m /h]
3 0.24 0.28 0.34 0.42
Pressure drop [bar] 0.10 0.10 0.10 0.10
Tab. 37 Flow rate / pressure drop (option W3)

2.16 Refrigeration dryer
2.16 Refrigeration dryer

Model

Model*
* Read off the dryer model from the dryer nameplate and enter it in the table.
Tab. 38 Refrigeration dryer: Model
Compressed air system
— ABT 60
Pressure drop [bar] — 0.2
(referred to 7 bar working
pressure)
Maximum permitted — 16
working pressure [bar]
Tab. 39 Refrigeration dryer: Compressed air system
Refrigerant system
The refrigeration dryer contains a refrigerant that is classified by the Kyoto Protocol as a fluorinated
greenhouse gas. This refrigerant is required for the function.
— ABT 60
Refrigerant — R-134a
Global warming potential — 1430
(GWP)
Charge quantity1) 2) [kg] — 0.8 / 0.8
Charge quantity as CO2
1) — 1.14 / 1.14
equivalent [t]
Max. working pressure — 21
[bar]
(high pressure side)
Max. working pressure — 16
[bar]
(low pressure side)
Safety pressure monitor: — 21
Cut-out pressure [bar]
1)
50Hz / 60Hz
2)
Volume of fluorinated greenhouse gases for which the refrigerant system was designed
Tab. 40 Refrigeration dryer: Refrigerant system

3.1 Basic instructions

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.
Disregard of warning or safety instructions can cause serious injuries!
➤ 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 operating manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
3.2 Specified use

The machine is intended solely for generating compressed air for industrial use. 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.
➤ Comply with the instructions in this operating 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 air for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated.
3.3 Improper use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Only use the machine as intended.
➤ Never direct compressed air at persons or animals.
➤ Use hot cooling air for heating purposes only if there is no risk to the health of humans or ani‐
mals. If necessary, hot cooling air should be treated by suitable means.
➤ Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in force.
3.4 User's responsibilities

3.4.1 Observe statutory and universally accepted regulations
These are, for example, nationally implemented European directives and/or applicable national leg‐
islation, safety and accident prevention regulations.

3.4 User's responsibilities
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.
3.4.2 Determining personnel

Suitable personnel are experts who, by virtue of their training, knowledge and experience as well
as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐
sible dangers involved.
Authorised operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the operating manual
relevant to operation,
■ they have received adequate training and authorization to operate electrical and compressed
air devices,
■ Additional qualifications for machines with refrigeration dryers:
─ they must have training and qualification for safe operation of refrigeration devices.
Authorised installation and maintenance personnel have the following qualifications:

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

The machine is subject to local inspection schedules.
Examples of German operation
➤ Carry out recurring inspections to DGUV Regel 100 – 500, chapter 2.11:
The user must ensure that the machine's safety devices are checked for function as required
or at least annually.
➤ Carry out oil changes to DGUV Regel 100 – 500, chapter 2.11.
The user must ensure that the cooling oil is changed as required or at least annually and the oil
change must be documented. Intervals may be varied if an analysis proves that the oil is still
usable.

3.5 Dangers
➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in §15.
Inspection Inspection interval Inspecting authority

Installation and equip‐ Before commissioning Approved supervisory body
ment inspection
Internal inspection Every 5 years after installation or Competent person
the last inspection (e. g. KAESER SERVICE technician)
Strength test Every 10 years after installation or Competent person
the last inspection (e. g. KAESER SERVICE technician)
Tab. 41 Inspection intervals according to Ordinance on Industrial Safety and Health
3.5 Dangers
Basic instructions
The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.5.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.
Electricity
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or re-commissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply isolator and verify the absence of any voltage.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or the electrical machine heating, for ex‐
ample.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the distribution network to ensure
that no compressed air can flow back into the machine.

3.5 Dangers
➤ De-pressurise all pressurised components and enclosures.

➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Compressed air quality
The composition of the compressed air must be suitable for the actual application in order to pre‐
clude health and life-threatening dangers.
➤ Use appropriate systems for air treatment before using the compressed air from this machine
as breathing air and/or for the processing of foodstuffs.
➤ Use foodstuff-compatible cooling oil whenever compressed air is to come into contact with
foodstuffs.
Spring forces
Springs under tension or compression store energy. Uncontrolled release of this energy can cause
serious injury or death.
Minimum pressure / check valves, pressure relief valves and inlet valves are powerfully spring-loa‐
ded.
➤ 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 activated.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before re-starting.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air lines, cool‐
ers, oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
The blowing-off of the pressure relief valve can be particularly loud.

3.5 Dangers
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

➤ Use only spare parts approved by the manufacturer for use in this machine.
➤ Use only genuine KAESER replacement parts on pressure bearing parts.
Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
Extending or modifying the compressor station
If dimensioned appropriately, pressure relief valves reliably prevent an impermissible rise in pres‐
sure. New dangers may arise if you modify or extend the compressed air station.
➤ When extending or modifying the compressed air system:
Check the blow-off capacity of pressure relief valves on air receivers and compressed air lines
before installing a new machine.
➤ If the blow-off capacity is insufficient:
Install pressure relief valves with larger blow-off capacity.
3.5.2 Safe machine operation

The following is information supporting you in the safe handling of the machine during individual
product life phases.
Personal protective equipment
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Suitable protective clothing (examples):

■ Safety work wear
■ Protective gloves

3.5 Dangers
■ Safety boots
■ Eye protection
■ Ear protection
Transport
The mass and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Assembly
➤ Use only electrical cables that are suitable and approved for the surroundings and electrical
loads applied.
➤ Never dismantle compressed air pipes until they are fully vented.
➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Installation
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 2014/34/EC "Equipment and Protective Sys‐
tems intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance: explosive or chemically instable gases and vapours,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in the warm exhaust air flow from other machines.

3.5 Dangers
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
➤ Check that there is no voltage on potential-free contacts.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Carry out regular inspections:
for visible damages,
of safety installations,
of the EMERGENCY STOP command device,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
De-commissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organisational Measures

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

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

3.6 Safety devices
Activity Danger area Authorised personnel

Transport Within a 3 m 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 1 m radius of the machine and its sup‐
ply cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Tab. 42 Danger Areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ 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 4.2.2.
3.7 Working life of safety functions

Pursuant to ISO 13849-1:2008 , Category and Performance Level (PL) of the machine's safety
functions have been analyzed and assessed:
Safety function Category Performance Level
Safety shut-down at excessive airend discharge 2 c
temperature
EMERGENCY STOP control device 1 c
Tab. 43 Category and Performance Level
The safety-relevant components of the safety functions are designed for a working life of 20 years.
The working life starts with the commissioning, and is not extended by times during which the ma‐
chine was not in use.
The following components are affected:

■ Resistance thermometer (Pt100 sensor for measuring the compression discharge temperature)
■ EMERGENCY STOP control device
■ Mains contactor
1. The components of the safety functions must be replaced by KAESER SERVICE after a work‐
ing life of 20 years.
2. Have the KAESER SERVICE check the reliability of the safety functions.

3.8 Safety signs
3.8 Safety signs

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

1 Danger of fatal injury from electric shock!
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and verify the
absence of any voltage.
2 Hot surface!
Risk of burns caused by contact with hot components
➤ Do not touch the surface.
➤ Wear long-sleeved garments (no synthetics such as polyester) and protec‐
tive gloves.
3 Risk of serious lacerations or even severing of extremities (fingers) from rotating
components.
➤ Operate the machine only with closed safety guards, access doors and pan‐
els.
➤ Switch off and lock out the mains isolating devices and verify the absence of
any voltage before opening any machine enclosure or guard.
4 Personal injury or damage to the machine by incorrect operation!
➤ Read and understand the service manual and all safety signs before switch‐
ing on this machine.
Risk of injury caused by an automatic machine start!
➤ Switch off and lock out the mains isolating devices and verify the absence of
any voltage before opening any machine enclosure or guard.
5 Risk of fatal injury caused by dismantling valves (spring-loaded or under pres‐
sure)!
➤ Do not open or dismantle valves.
➤ Call an authorised Service Technician in the event of a fault.

3.9 Emergency situations
Position Symbol Meaning

6 Serious injury, particularly to the eyes, can result from foreign objects being
thrown out from rotating components.
➤ Do not allow anything to fall through the ventilation grille
➤ Do not work above the machine if it is switched on.
8 Bearing damage due to re-greasing in standstill!
➤ Re-grease the bearings only with the motor running.
➤ Use only ESSO UNIREX N3 bearing grease.
➤ Adhere to the prescribed maintenance interval and grease quantity.
Tab. 44 Safety signs
3.9 Emergency situations

3.9.1 Correct fire fighting
Suitable measures
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
➤ Shut off supply lines if possible.
Mains disconnecting device (all poles)
Cooling water (if present)
Heat recovery (if present)
➤ Warn and move endangered personnel to safety.
➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
➤ Suitable extinguishing media:

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water
3.9.2 Treating injuries from handling cooling oil

Eye contact:
Cooling oil can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.

3.10 Warranty
Skin contact:
Cooling oil may irritate after prolonged contact.

➤ Wash thoroughly with skin cleaner, then with soap and water.
➤ Contaminated clothing should be dry-cleaned before reuse.
Inhalation:
Cooling oil mist may make breathing difficult.

➤ Clear air passages of oil mist.
➤ Seek medical help if difficulty with respiration continues.
Ingestion
➤ Wash out the mouth immediately.

➤ Do not induce vomiting.
➤ Seek medical aid.
3.9.3 Injury from Handling Refrigerant

Eye contact:
Severe eye irritation, watering, reddening and swelling of the eyelids.

Risk of caustic burns and frostbite.
➤ Open eyelids wide to allow product to evaporate.
➤ Hold the eyelid wide and rinse the eye with running water.
➤ Consult an ophthalmologist if you experience lasting pains.
Skin contact:
Initially a sensation of chill, skin may redden subsequently.

Risk of frostbite.
➤ Allow the product to evaporate.
➤ Rinse with lukewarm water.
➤ Consult a physician if experiencing lasting pain or reddened skin.
Inhalation:
At high concentrations, risk of cardiac irregularity (arrhythmia).

At very high concentration, risk of asphyxia caused by oxygen deficiency.
➤ Remove victim to the fresh air.
➤ If necessary Respiration with respirator or administration of oxygen.
➤ Consult a physician if experiencing breathing or nerve complaints.
3.10 Warranty
This operating manual does not contain any independent warranty commitment. Our general terms
and conditions apply with regard to warranty.

3.11 Environment protection
A condition of our warranty is that the machine is used solely for the purpose for which it is inten‐
ded and under the conditions specified.
Due to the multitude of applications for which the machine is suitable, the user is obliged to deter‐
mine its suitability for his specific application.
Furthermore, we do not assume any warranty obligation for damages caused by:
■ the use of unsuitable parts or operating materials,
■ arbitary modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.11 Environment protection

The operation of this machine may cause dangers for the environment.
➤ Do not allow cooling oil to escape to the environment or into the sewage system.
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
ment protection regulations.
➤ Observe national regulations.
This applies particularly to parts contaminated with compressor cooling oil.

4.1 Enclosure

4.1 Enclosure
Fig. 3 Enclosure overview

1 Control cabinet door 3 Access door
2 Latch 4 Panel (removable)
When closed, the enclosure 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 Machine function

The description uses an air-cooled machine as an example.

Fig. 4 Machine overview

1 Inlet valve 7 Oil separator tank
2 Minimum pressure check valve 8 Air filter
3 Compressor drive motor 9 Oil/air cooler
4 Oil filter 10 Add-on cabinet for refrigeration dryer
5 Compressor block 11 Centrifugal separator
6 Control cabinet 12 Condensate drain
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 ro‐
tors 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. Air pressure
within the machine keeps the oil circulating. A separate pump is not necessary.
A temperature-regulating valve driven by an electric motor keeps the cooling oil at optimum tem‐
perature. Together with SIGMA CONTROL 2 , the electronic thermal management ( Electronic
Thermo Management – ETM ) uses various parameters to keep the cooling oil temperature as low
as possible. A low cooling oil temperature increases the machine's energy efficiency.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pres‐
sure / check valve 2 into the air cooler 9 . The minimum pressure/check valve ensures sufficient
internal pressure to maintain cooling oil circulation.
The aftercooler cools the compressed air temperature to approximately 5K to 10K above the ambi‐
ent temperature. A major portion of the existing humidity is removed from the compressed air and
drained via the cyclone separator 11 with condensate drain 12 .

4.2.1 Refrigeration dryer
Fig. 5 Refrigeration dryer

10 Refrigeration dryer
12 Condensate drain
The downstream refrigeration dryer removes moisture from the compressed air.
The condensate drain ejects the precipitate.
4.2.2 Safety devices

The following safety devices are provided and may not be modified in any way.
■ EMERGENCY STOP control device:
Stops the machine immediately in an emergency situation. The motor is stopped. The pressure
system is vented.
■ Pressure relief valve:
The pressure relief valve protects the system against excessive pressure. It is factory set.
■ Safety pressure monitor (Machine with refrigeration dryer):
The safety pressure monitor protects the refrigerant circuit against excessive pressure. It can‐
not be set.
■ Housing and covers for moving parts and electrical connections:
Protect against accidental contact.
4.2.3 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.

4.3 Operating panel SIGMA CONTROL 2

Keys
Fig. 6 Keys - overview
Position Name Function

1 «OFF» Switches the machine off.
2 «ON» Switches the machine on.
3 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Enter» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.
7 «Left» Jumps to the left.
Moves the cursor position to the next left field.
8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.


13 «Time control» Switches time control on and off.
Tab. 45 Keys
Indicators
Fig. 7 Indicators – overview

14 Display Graphic display with 8 lines and 30 characters per line.
15 Fault Flashes red to indicate a machine fault.
Continuous red light after acknowledgement.
16 Communications Continuous red light to indicate a faulty communication connec‐
error tion, or an external fault message without machine shut-down.
17 Warning Flashes in yellow in the following events:
■ Maintenance work due
■ Warning message
Continuous yellow light after acknowledgement.

18 Voltage applied to Continuous green light when voltage is applied to the controller.
controller
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Time control Continuous green light when the machine is controlled by the tim‐
er.

4.4 Operating modes and control modes

23 ON Continuous green light when the machine switched on.
Tab. 46 Indicators
RFID reader
RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2 .
A suitable transponder is the KAESER RFID equipment card. Two of them have been provided
with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 8 RFID reader

24 RFID RFID reader for the communication with a suitable RFID transponder.
Tab. 47 RFID reader
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.

4.4.1 Machine operating modes
STOP
The machine is connected to the power supply.

The voltage applied to controller LED lights green.
The machine is switched off. The on LED is extinguished.
READY
The machine has been activated with «ON»:

■ The on LED lights green.

■ The drive motor is stopped.

■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air system.
■ The venting valve is open.
The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.

■ The inlet valve is open.
■ The compressor block delivers compressed air to the system.
IDLE
The compressor motor runs unloaded with low power consumption.

■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air system.
■ The venting valve is open.
A small volume of air circulates through the bypass bore in the inlet valve, through the compressor
block and back to the inlet valve via the venting line.
4.4.2 Control modes

Using the selected control mode, the controller switches the machine between its various opera‐
tional states in order to maintain the gauge working pressure between the set minimum and maxi‐
mum values, regardless of the drawn compressed air volume. The control mode also rules the de‐
gree of energy efficiency of the machine.
The shortest possible times for the various parameters is preset by the factory to ensure that the
compressor motor earlier and more frequently is at standstill. If you want to change these parame‐
ters, select the shortest possible times in order for the machine working energy-efficiently.
The machine-dependant venting time between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The following control modes can be set:

■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
Supplementary mechanical flow rate regulation:

Option C1 ■ MODULATING control

Energy-efficient control modes for various applications:

Application Recommended control mode
Compressed air station with one machine or several machines VARIO
supplying similar volumes.
Machine for peak load in a compressed air station VARIO
Machine for intermediate load in a compressed air station DYNAMIC1)
Machine for basic load in a compressed air station DYNAMIC1)
1)
At exceedingly high pressure fluctuations or frequent drive motor starts (current peaks), switch
from DYNAMIC to VARIO.
Tab. 48 Energy-saving control modes
The QUADRO control mode is preset by the factory, unless a different agreement has been made
with the manufacturer.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
QUADRO
In contrast to DUAL mode, the machine will switch in QUADRO after short periods between LOAD
to READY after being in IDLE.
Following extended times in the various operating modes, the machine switches from LOAD to
READY.
In this event, the controller considers the time in READY mode as standstill time. The time in LOAD
and IDLE operating modes are taken as minimum runtime.
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
DYNAMIC
In contrast to the the DUAL regulating mode, the machine will switch from LOAD to READY in
DYNAMIC mode at low drive motor temperature.
At higher motor temperatures, the machine switches to IDLE until the compressor motor has
cooled down enough. Subsequently, the machine to READY.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is
stopped.
Option C1 MODULATING control
The MODULATING control is an additional mechanical regulation. It continuously changes the flow
rate within the machine's control range.

4.5 Refrigeration Dryer Control Modes
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD)
The load and power consumption of the drive motor rises and falls with the air demand.
4.5 Refrigeration Dryer Control Modes

The controller can operate in the following modes:
■ CONTINUOUS
■ TIMER
CONTINUOUS
The refrigeration dryer will remain activated even when the machine is in standby.
TIMER
The refrigeration dryer is switched on and off by a timer when the machine is in standby. In this
mode, the operating temperature is held within tight limits.
This mode of control is set up at the factory.
Which control mode is the most practical, and when?
Control mode Advantage Disadvantage

CONTINUOUS Constant dew point. Higher power consumption when the machine
is in standby mode.
TIMER Lower power consumption when Brief increase in dew point when the compres‐
the machine is in standby mode. sor re-starts
Tab. 49 Refrigeration dryer control modes
4.6 Options
The options available for your machine are described below.
4.6.1 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 9 Machine mountings
4.6.2 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.

4.6 Options
Fig. 10 Cooling air filter mat (option K3)

1 Cooling air filter mat
4.6.3 Option W2/W3

Heat recovery
The cooling oil circuit includes 2 valves influencing the cooling oil temperature:
■ Oil temperature regulator
■ Thermostatic valve
The thermostatic valve of the heat recovery system opens first and releases surplus heat into the
heat recovery system. If the heat recovery system cannot remove sufficient heat, the oil tempera‐
ture regulator of the machine opens to additionally release the cooling circuit via the oil cooler.
The heat available for recovery depends on the individual operating conditions of the machine.
If the heat recovery system is activated, the air discharge temperature is usually higher than in ma‐
chines without heat recovery, reducing the efficiency of the compressed air generation.
➤ Activate the heat recovery only if you can use the machine's waste heat.
See the user manual of the SIGMA CONTROL 2 for information regarding the activation and
deactivation of the heat recovery.
A plate-type heat exchanger is installed for heat recovery.
The plate-type heat exchanger transfers heat from the cooling oil to a heat-receiving medium.
Fig. 11 Function of the heat recovery

1 Plate-type heat exchanger

5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated have a decisive effect on safety.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety notes
Disregard of safety notes can cause unforeseeable dangers!

➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 2014/34/EC "Equipment and Protective Sys‐
tems intended for use in Potentially Explosive Atmospheres".
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

■ Maintain ambient temperature and humidity
■ Ensure the appropriate composition of the air within the machine room:
─ clean with no damaging contaminants (e.g., dust, fibres, fine sand)
─ free of explosive or chemically unstable gases or vapours
─ free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulfide.
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 of the machine room is provided 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 mass of the machine.

5.2 Installation conditions
Fig. 12 Recommended machine placement and dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Air inlet aperture
1. NOTICE!
Ambient temperature too low.
Frozen condensate and highly viscous cooling oil can cause damage when starting the ma‐
chine.
➤ Make sure that the temperature of the machine is at least +3 °C before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
2. Ensure adequate lighting so that all work on the machine can be carried out without danger or
hindrance.
3. Ensure that the indicators can be read without glare and that the controller display cannot be
damaged by direct sunlight (UV radiation).
4. Ensure that all intake and exhaust apertures of the enclosure remain opened.
5. If installed outdoors, the machine must be protected from frost, direct sunlight, dust and rain.
5.2.2 Ensuring the machine room ventilation

Adequate ventilation of the machine room has several tasks:
■ It prevents subatmospheric pressure in the machine room.
■ It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐
tions.
➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of
the machine room.
1. Ensure that the flow volume of fresh air is at least the same as the volume taken by the ma‐
chine and exhaust fan from the machine space.
2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac‐
tually open.

5.3 Operating the machine in a compressed air network
3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
4. Ensure clean air in order to support the proper functioning of the machine.
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 cool‐
ing.
➤ Consult the KAESER SERVICE representative before deciding on:
■ Design of the exhaust air ducting
■ Transition between the machine and the exhaust air duct
■ Length of the ducting
■ Number of duct bends
■ Design of flaps or shutters
Further information Further information on the design of exhaust air ducts can be found in chapter 13.3.
5.3 Operating the machine in a compressed air network

If the machine is supplying an air network, the network working pressure may not exceed 16 bar
(China: 15.9 bar).
When charging a fully vented air system there is generally a very high rate of airflow through the air
treatment devices. These conditions are detrimental to correct air treatment. Air quality suffers.
To ensure the desired air quality when charging a vented air network, we recommend the installa‐
tion of an air main charging system.
➤ Consult KAESER for advice on this subject.

6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Installation work may only be carried out by authorised personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
When working on live components
➤ Work on electrical equipment may only be carried out by authorised electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
When working on the compressed air system
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
When working on the drive system
in serious injury.
Further information Details of authorised personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

6 Installation
6.2 Reporting Transport Damage
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 Connecting the machine with the compressed air network

Condensate in the compressed air network can damage the pipework:
➤ Install only corrosion-resistant pipes.
➤ Use fluoroelastomers as sealing material for seals.
➤ Note the electro-chemical voltage sequence.
➤ Consult with KAESER for suitable materials for the compressed air network.
Precondition The compressed air system is vented completely to atmospheric pressure.
Fig. 13 Compressed pipework

1 Flexible pressure line or compensator
2 Shut-off valve
➤ Do not induce any forces into the machine for which the compressive forces must be bal‐
anced by bracing.
1. WARNING!
Serious injury or death can result from loosening or opening components under pressure.
➤ Vent all pressurized components and enclosures.
2. A shut-off valve must be installed by the user in the connection line.
3. Connect the machine to the compressed air network with a flexible pressure line or appropriate
compensator.
Further information The dimensional drawing in chapter 13.3 provides the size and position of the connection ports.
6.4 Connecting the condensate drain

A threaded hose connection is provided to attach a condensate drain hose.
The condensate must be able to drain freely.
➤ Only machines with 16 bar maximum permissible working pressure may be connected to
the condensate collecting line.

6 Installation
6.4 Connecting the condensate drain
Fig. 14 illustrates the recommended installation.

Condensate flows downward in the collecting line. This prevents condensate flowing back to the
compressor.
If condensate flows at several points into the condensate collecting line, you must install shut-off
valves in the condensate lines to shut the condensate line off before commencing maintenance
work.
Condensate line
Feature Value
Max. length1) [m] 15
Max. delivery head [m] 5
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact the manufacturer before installation.
Tab. 50 Condensate line
Condensate collecting line
Feature Value
Gradient [%] >1
Max. length1) [m] 20
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact KAESER before installation.
Tab. 51 Condensate collecting line
Compressed air flow Line cross-section ["]

rate1) [m3/min]
<10 3/4
10 – 20 1
21 – 40 1 1/2
>40 2
1)
Compressed air flow rate as guide for the condensate volume to be expected
Tab. 52 Condensate collecting line: Line cross-section

6 Installation
6.5 Connecting the external pressure transducer
Fig. 14 Connecting the condensate drain

1 Threaded connection 5 Shut-off valve
2 Condensate line A Delivery head
3 Condensate collecting line B Length of the condensate collecting line
4 Screw plug
Depending on the machine model, you may have several condensate drains.
➤ Directly connect every condensate drain to the condensate collecting line.
➤ Collect the condensate in a suitable container and dispose of in accordance with environ‐
mental regulations.
Further information The dimensional drawing in chapter 13.3 provides the size and position of the connection port.
6.5 Connecting the external pressure transducer

Material Retrofit kit: "External pressure transducer SIGMA CONTROL 2 "
Use suitable screened, copper-core cable (e.g.: LIYCY 2x0,75 mm2 for ambient temperature up to
30 °C and laying method C).
Precondition The power supply isolating device is switched off,

the device is locked off,
the absence of any voltage has been verified.
Cable length between the machine and the pressure transducer: <30 m
By means of a pressure transducer, the pressure in the compressed air network can be measured
at any selected location and this signal used to regulate the compressor.
This ensures optimum compressor regulation with regard to the network pressure at the selected
location.
Safety monitoring of the machine's internal pressure is unaffected.
Your authorized KAESER Service Technician will be glad to provide support on planning and
executing an individual solution.
1. Install the pressure transducer at the selected location in the compressed air network.
2. Using a suitable cable, connect the pressure transducer to a spare analog input.
➤ Connect as large an area of the screening as possible to the mounting plate in the control
cabinet or use an EMC fitting to make contact.

6 Installation
6.6 Refrigeration dryer: Connecting the transformer according to the mains supply.
3. When commissioning the machine with SIGMA CONTROL 2 , select the < Network actual
pressure > setting in the < AII > menu.
4. Select and activate the used analog input ( AII ).
Further information The electrical diagram in chapter 13.4 contains further details of the pressure transducer connec‐
tion.
6.6 Option T2
Refrigeration dryer: Connecting the transformer according to the
mains supply.
The refrigeration dryer transformer has tappings for various mains voltages.
1. Check that the correct connections are made for the supply voltage provided for the machine.
2. If necessary, re-connect the transformer to match the mains supply voltage.
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.
6.7 Connecting the machine with the power supply

Precondition The power supply is switched off,
The tolerance limits of the mains voltage (power supply) are within the permissible tolerance limits
of the rated voltage (machine).
1. The power supply must only be connected by authorised installation personnel or an author‐
ised electrician.
2. Carry out safety measures as stipulated in relevant regulations (IEC 364 or DIN VDE 0100, for
example) and in national accident prevention regulations (BGV A3 in Germany). In addition,
observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐
nect in response to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.
5. The user is required to fit the machine with a lockable isolating device which must comply with
the requirements of EN60204-1:2006, 5.3.
This could be, for example, a load disconnect switch with upstream fuse. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the control voltage transformer is connected according to the supply voltage.
If not, change the connections to suit the power supply voltage.
7. DANGER!
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check the absence of
any voltage.
8. Connect the machine to the power supply.
9. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.

6 Installation
6.8 Options
6.8 Options
6.8.1 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.
6.8.2 Option W2/W3

Connecting the heat recovery system
➤ Take the electrochemical series into consideration and choose suitable materials for con‐
nections.
➤ Keep the effect of pressure surges on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.
➤ Avoid very low inlet temperatures of the heat transfer medium as it can cause condensa‐
tion. 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.
Fig. 15 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.
Actuating pressure and blow-off capacity of the safety valve are governed by the user's in‐
stallation design. The technical specification of the heat exchanger must be taken into con‐
sideration.
2. Connect the supply lines and fittings.
3. Open the shut-off valve 10 at the inlet A .

6 Installation
6.8 Options
4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the
heat transfer medium.
5. Bleed the lines.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐
tion ports.

7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.

➤ Commissioning tasks may only be carried out by authorised personnel!
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
➤ Work on electrical equipment may only be carried out by authorised electricians.
➤ Check that there is no voltage on floating relay contacts.
When working on the compressed air system
pressure.
in serious injury.
Further information Details of authorised personnel are found in chapter 3.4.2.


7 Initial Start-up
7.2 Instructions to be observed before commissioning or re-commissioning
7.2 Instructions to be observed before commissioning or re-commis‐

sioning
Incorrect or improper commissioning can cause injury to persons and damage to the machine.
➤ Commissioning may only be carried out by authorised installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage
Storage period Remedy

longer than:
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorised KAESER Service Tech‐
nician.
36 months ➤ Have the overall technical condition checked by an authorised
KAESER Service Technician.
Tab. 53 Re-commissioning after storage
7.3 Checking installation and operating conditions

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

chapter
➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.7
➤ Are the tolerance limits of the mains voltage (power supply) within 13.4
the permissible tolerance limits of the rated voltage (machine)?
(see nameplate in the control cabinet)
➤ Are the power supply cable conductor cross-sections and fuse rat‐ 2.14
ings adequate?
➤ Drive motor overload protection switch set according to the mains 7.4
voltage?
➤ Fan motor overload protection switch set according to the mains volt‐ 7.5
age?
➤ Option T2: Check that the correct connections are made for the sup‐ 6.6
ply voltage provided for the machine.
➤ Have all electrical connections been checked for tightness? –
➤ Has the connection to the air system been made with a shut-off valve 6.3
and a hose or compensator?
➤ Condensate drain connected? 6.4

7 Initial Start-up
7.4 Setting the overload protection cut-out
To be checked See Confirmed?

chapter
➤ 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? 6.8.1
(Option H1)
➤ Are all access doors closed and latched and removable panels in –
place and secured?
Tab. 54 Installation 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 cur‐
rent is 0.58-times the rated motor current.
To prevent the overload protection cut-out from being triggered by voltage fluctuations, tempera‐
ture influences or component tolerances, the setting can be higher than the arithmetical phase cur‐
rent.
➤ 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 Pouring cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to 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 de-pressurised oil separator tank.
Chapter 10.16 provides detailed information on how to drain cooling oil from the oil separator tank.

7 Initial Start-up
7.6 Pouring cooling oil into the airend
Material 1 litre cooling oil from separator tank

The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar.
Fig. 16 Inlet valve oil filling port

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

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
Fig. 17 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
1. Unscrew 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 Initial Start-up
7.7 Activating and deactivating the MODULATING control
7.7 Option C1
Activating and deactivating the MODULATING control
Use a shut-off valve to activate and deactivate the MODULATING control. If the MODULATING
control is deactivated, the machine always delivers the maximum possible flow rate in LOAD mode.
MODULATING control Shut-off valve

switch on open
switch off close
Tab. 55 MODULATING control: Setting the shut-off valve

Fig. 18 MODULATING control: Setting the shut-off valve

1 Control valve (proportional control)
2 Shut-off valve
➤ Open or close the shut-off valve, depending on the required control mode.
The regulating valve is factory set. Consult with KAESER SERVICE before changing.
7.8 Starting the machine for the first time

Precondition Nobody is working at the machine.
All access doors are closed.
All removable panels are in place and secured.
1. Open the shut-off valve to the air network.

2. Switch on the power supply isolating device.
After the controller has carried out a self-test, the green Controller on LED is lit continuously.
3. If required:
Change the display language as described in chapter 7.10.

7 Initial Start-up
7.9 Setting the network setpoint pressure
4. Press the «ON »key.

The compressor motor runs up and after a short time the machine switches to LOAD and deliv‐
ers compressed air.
➤ Watch for any faults occurring in the first hours of operation.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
Does the machine stop when the compressor motor rotates in the wrong direction?
➤ Switch off and lock out the power supply isolating device, and verify the absence of volt‐
age.
➤ Changeover phase lines L1 and L2.
➤ Acknowledge any existing alarm messages and switches the machine on again.
7.9 Setting the network setpoint pressure

The system pressure pA 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 compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To improve the switching 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 2 operating manual.
7.10 Setting the display language

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
6.1 bar 80.0 ° C
–––––––– de_DE Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.

7 Initial Start-up
7.10 Setting the display language
Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.

8 Operation
8.1 Switching on and off
8 Operation
8.1 Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.
Fig. 19 Switching on and off

1 ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Voltage applied to controller LED
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply isolating device.

The Voltage applied to controller LED lights green.
2. Press the «ON »key.
The ON LED lights green.
If a power failure occurs, the machine is not prevented from re-starting automatically when
power is resumed.
It can re-start automatically as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).
8.1.2 Switching off

1. Press the «OFF» key.
The machine switches to IDLE and the IDLE LED flashes. The SIGMA CONTROL 2 displays
Stopping . The ON LED extinguishes as soon as the automatic shut-off action is completed.
2. Switch off and lock out the power supply disconnecting device.

8 Operation
8.2 Switching off in an emergency and switching on again
Result The Voltage applied to controller LED extinguishes. The machine is switched off and disconnected
from the mains supply.
In rare cases, you may want to shut down the machine immediately and cannot wait until the
automatic shut-down process is finished.
➤ Press «OFF» once again.
8.2 Switching off in an emergency and switching on again

The EMERGENCY STOP control device is located below the control panel.
Fig. 20 Switching off in an emergency

9 EMERGENCY STOP control device
Switching off
➤ Press the EMERGENCY STOP control device.
Result The EMERGENCY STOP control device remains latched after actuation.
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 control device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Using the remote control for switching on and off

Precondition A link to the remote control centre exists.

8 Operation
8.4 Using the timer for switching on and off
Fig. 21 Using the remote control for switching on and off

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

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 56 Machine identification
2. Label the starting device in the remote control centre as follows:
Remote control: Risk of injury caused by unexpected starting!

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 57 Remote control identification
3. Press the «remote control» key.

The remote control LED lights. The machine can be remotely controlled.
8.4 Using the timer for switching on and off

Precondition The clock is programmed.

8 Operation
8.5 Interpreting operation messages
Fig. 22 Using the timer for switching on and off

1 «Timer» key
2 Timer LED
1. Attach an easily seen notice warning of time-controlled operation:
Time control: Risk of injury caused by unexpected starting!

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 58 Machine identification
2. Press «Timer».
The Timer LED lights. The timer switches the machine on and off.
8.5 Interpreting operation messages

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O .
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
8.6 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle:
■ Message coming: LED flashes
■ Message acknowledged: LED illuminates
■ Message going: LED off
or
■ Message coming: LED flashes

■ Message going: LED flashes
■ Message acknowledged: LED off

8 Operation
8.6 Acknowledging alarm and warning messages
Fig. 23 Acknowledging messages

10 Warning LED (yellow)
11 Fault LED (red)
12 «Acknowledge» key
Alarm message
An alarm shuts the machine down automatically. The Fault LED flashes red.
The system displays the appropriate message.
Precondition The fault has been rectified
➤ Acknowledge the message with the «acknowledge» key.

The Fault LED extinguishes.
The machine is again ready for operation.
If the machine was switched off with the EMERGENCY STOP button:
➤ Unlatch the EMERGENCY STOP button (turn in direction of the arrow) before acknowl‐
edging the alarm message.
Further information Please refer to the SIGMA CONTROL 2 operating manual for a list of possible fault messages dur‐
ing operation.
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the Warning
LED flashes yellow.
The system displays the appropriate 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 Please refer to the SIGMA CONTROL 2 operating manual for a list of possible warning messages
during operation.


Error messages are classified in these categories:
■ Warning:
─ Warning messages W
■ Fault (with indication):
─ Alarm messages A
─ System messages Y
─ Diagnostic messages D
■ Other faults (without indication): See chapter 9.2
The messages valid for your machine are dependent on how the individual machine is equipped.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorised KAESER SERVICE representative.
Further information See the operating manual of SIGMA CONTROL 2 for details regarding the various messages.
9.2 Other faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call KAESER SERVICE.
compressed air. opening partially.
Venting valve not closing. Call KAESER SERVICE.
Leaks in the pressure system. Check pipework and connec‐
tions for leaks and tighten any
loose connections.
Compressed air demand ex‐ Check the air system for leaks.
ceeds the volumetric flow rate Shut down consumer(s).
from the compressor.
Hose coupling or maintenance Remove coupling or mainte‐
hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Cooling oil runs out of the in‐ Oil level in the oil separator Drain off oil until the correct lev‐
take filter. tank too high. el is reached.
Inlet valve defective. Call KAESER SERVICE.
Compressor switches be‐ Receiver too small. Increase size of receiver.
tween LOAD and IDLE more Airflow into the compressed air Increase air pipe diameters.
than twice per minute. network restricted. Check filter elements.
The differential between cut-in Check switching differential.
and cut-out pressure too is
small.

9.2 Other faults
Fault Possible cause Remedy

Cooling oil leaking into the ma‐ Hose coupling or maintenance Remove coupling or mainte‐
chine interior. hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Oil cooler leaking. Call KAESER SERVICE.
Leaking pipe joints. Tighten pipe joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐
high. ing oil.
Oil separator cartridge split. Changing the oil separator car‐
tridge
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line clogged. Check the dirt trap strainer in
the oil return line.
Tab. 59 Other faults and remedies

10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.

➤ Maintenance work may only be carried out by authorized personnel.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 60 Advise others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Check that there is no voltage on potential-free contacts.
When working on pressure system
pressure.

10 Maintenance
10.2 Following the maintenance plan
in serious injury.
Further information Details of authorized personnel are found in chapter 3.4.2.


10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for KAESER original components
with 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 condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.21.
10.2.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters moni‐
tor the operational state of important functional devices. Required maintenance work is shown on
SIGMA CONTROL 2 .
Precondition Maintenance performed and

maintenance message acknowledged.
➤ Reset the maintenance interval counter as described in the SIGMA CONTROL 2 operating
manual.
10.2.3 Regular maintenance tasks

The table below lists maintenance tasks required.
The refrigeration circuit is a closed system. Repairs may only be carried out by certified personnel.

10 Maintenance
➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient
and operating conditions into account.
Interval Maintenance task see chapter

Weekly Check the cooling oil level. 10.13
Control cabinet: 10.3
Check the filter mat
Check the condensate drain. 10.20
up to 1000 h Clean the cooler. 10.4
Option K3: 10.5
Check the filter mat.
Clean the refrigerant condenser. 10.19
up to 3000 h Option K3: 10.5
Change the filter mat.
Control cabinet: 10.3
Change the filter mat.
up to 6000 h Condensate drain: 10.20.2
Every 2 years at the lat‐ Change the Service Unit
est.
Display: Change the air filter. 10.7
SIGMA CONTROL 2 Maintain the motor bearings. 10.8
Check the coupling. 10.9
Display: Change the oil filter. 10.17
SIGMA CONTROL 2
at least annually
Display: Change the oil separator cartridge. 10.18
SIGMA CONTROL 2
Every 3 years at the lat‐
est.
Variable, see table 62 Change the cooling oil. 10.16
Annually Check the pressure relief valve. 10.10
Check the function: 10.11
Safety shut-down due to excessive airend discharge tem‐
perature
Check the EMERGENCY STOP control device. 10.12
Check the cooler for leaks. 10.4
Maintain the heat recovery system. 10.6
Check that all electrical connections are tight. –
h = operating hours
Tab. 61 Regular maintenance tasks

10 Maintenance
10.2.4 Cooling oil Change interval

Duty cycles and ambient conditions are important factors influencing the number and length of the
oil change intervals.
KAESER SERVICE will support you in determining appropriate intervals and provide informa‐
tion on the possibilities of oil analysis.
➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary; log the results in table 62 for fu‐
ture reference.
Maximum permissible oil change interval

[operating hours/years]
SIGMA FLUID Favourable operating Unfavourable operat‐ My operating condi‐
conditions* ing conditions tions
S-460 6000**/2 4000/1
S-570 6000**/2 4000/1
MOL 3000/1 2000/1
FG-460 3000/1 2000/1
FG-680 3000/1 2000/1
PANO‐ 3000/1 2000/1
LIN HLP SYNTH 46
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Change intervals of >6000 perating hours are not permissible without an oil analysis.
Tab. 62 Cooling oil Change intervals
10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Have an authorized KAESER SERVICE technician carry out service tasks.
➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐
count.
Interval Service task

Display: Service valves.
SIGMA CONTROL 2 Compressor drive motor:
Replace the motor bearings.
Display: Fan motor
SIGMA CONTROL 2 Replace the motor bearings.
est.
up to 36000 h Have the plastic pipes and hose lines been replaced.
est.
h = operating hours

10 Maintenance
10.3 Control cabinet: Clean or renew the filter mat
Interval Service task

up to 36000 h Replace the control cabinet fan.
After 20 years at the lat‐ Replace safety-relevant components of the safety functions.
est
h = operating hours
Tab. 63 Regular service tasks
10.3 Control cabinet: Clean or renew the filter mat

A filter mat is placed behind every ventilation grille. Filter mats protect the control cabinet from in‐
gress of dirt. If the filter mats are clogged, adequate cooling of the components is no longer ensur‐
ed. In such a case, clean or replace the filter mats.
Material Warm water and household detergent

Spare parts (as required)

The machine has cooled down.
Fig. 24 Switching cabinet ventilation

1 Ventilation grille
2 Filter mat
1. Carefully remove the ventilation grille and take out the filter mat.
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Change the filter mat if cleaning is not possible or if the change interval has expired.
4. Insert the filter mat in the frame and latch in the ventilation grille.

10 Maintenance
10.4 Cooler maintenance
10.4 Option K1
Cooler maintenance
Regularly clean the cooler. This ensures reliable cooling of the machine and the compressed air.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the motors resulting in increased wear
and tear.
➤ Have the authorised KAESER Service clean the cooling air ducts.
Material Brush and vacuum cleaner

Face mask (as required)

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?
➤ Have stubborn clogging removed by an authorized KAESER Service Technician.
Check the cooler for leaks
➤ Carry out visual inspection: Did cooling oil escape?

10 Maintenance
10.5 Cleaning or Renewing the Cooling Air Filter Mat
Is a cooler leaking?
➤ Have the defective cooler repaired immediately by KAESER Service.
10.5 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat help to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer ensured.
Material Warm water and household detergent

Spare parts (as required)
Precondition The machine is switched off.
Fig. 26 Cooling air filter mat

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

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

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

Use a screwdriver to turn the fixings 90° clockwise until they latch.

10 Maintenance
10.6 Maintaining the heat recovery system
10.6 Option W2/W3

Maintaining 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 depend‐
ant on the characteristics of the heat transfer medium.
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 supply disconnecting device is switched off.

The disconnecting device is locked off.
A check has been made that no voltage is present.
1. Check the heat exchanger visually for leaks.

2. Have KAESER Service check the heat exchanger for internal leaks and clean if contaminated.
10.7 Change the air filter

Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress into the pressure system and cause damage to the machine.
Do not clean the air filter element. A damaged air filter element can permit dirt to ingress the
pressure system and cause damage to the machine.
Material Spares
Precondition The supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
Fig. 27 Air filter maintenance

1 Nut
2 Air filter element
3 Cover
1. Unscrew the nuts 1 and lift out the cover 3 .

2. Remove the air filter element.
3. Clean all parts and sealing surfaces.

10 Maintenance
10.8 Motor maintenance
4. Insert the new air filter element.

5. Insert the cover in the machine and secure with nuts 1 .
6. Close all access doors and replace all enclosure panels.
7. Switch on the power supply and reset the maintenance interval counter.
10.8 Motor maintenance

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

Cleaning cloth
Compressor motor:
The lubricating nipples of both motor bearings are located directly at the compressor motor.
The required quantity of grease is stated on the motor nameplate.
Precondition Compressor running in IDLE.

Wear suitable protective equipment:
Safety goggles, safety gloves, and ear protection.
1. Clean the nipple with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.
Option K1 Fan motor
➤ Have the fan motor bearings checked by a KAESER Service Technician during the course of a
visit.
10.9 Checking the Coupling

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

10 Maintenance
10.10 Testing the pressure relief valve
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
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
1. Remove the securing screws and take off the safety screen.
2. Turn the coupling my hand and look for damage or colour change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Has the coupling cracks or colour changes?
➤ Have a damaged coupling changed by an authorised KAESER Service Technician.
10.10 Testing the pressure relief valve

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blow off protection and air system pressure monitoring are switched off during the test. In normal
operation, the blow-off protection will switch off the machine before the pressure relief valve re‐
sponds. During the inspection, the blow-off protection will switch off the machine only when the ac‐
tivating pressure of the pressure relief valve has been exceeded by 1 bar.

10 Maintenance
10.11 Check the safety shut-down due to excessive airend discharge temperature.
➤ Follow the detailed description of this procedure in the SIGMA CONTROL 2 operating
manual
➤ Never operate the machine without a correctly functioning pressure relief valve.
➤ Have a defect pressure relief valve replaced immediately.
WARNING
Excessive noise is caused when the pressure relief valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear hearing protection.
1. Close the user's shut-off valve between the machine and the air distribution network.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Log on to SIGMA CONTROL 2 with access level 2.
4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. WARNING!
Risk of burns due to released cooling oil and compressed air when blowing off the pressure
relief valve!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear eye protection.
6. End the test as soon as the pressure relief valve blows off or working pressure exceeds the
activating pressure of the pressure relief valve by nearly 1 bar.
7. If necessary, vent the machine and replace the defective pressure relief valve.
8. Deactivate the test function
9. Open the user's shut-off valve between the machine and the air distribution network.
10.11 Check the safety shut-down due to excessive airend discharge

temperature.
The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
The machine does not shut down?
➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐
nician.

10 Maintenance
10.12 Testing the EMERGENCY STOP device
10.12 Testing the EMERGENCY STOP device
Fig. 29 Testing the EMERGENCY STOP device

9 EMERGENCY STOP control device
Precondition The compressor motor is running.
1. Press the EMERGENCY STOP control device.

The compressor motor stops, the pressure system is vented, and the machine is prevented
from automatically re-starting.
The compressor motor does not stop?
The safety function of the EMERGENCY STOP device is no longer ensured.
➤ Shut down the machine immediately and call KAESER Service.
2. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
3. Acknowledge the alarm message.
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 lower the pressure at the compressed air outlet, the higher the speed.
SIGMA CONTROL 2 displays this value.
Precondition The machine has been running at least 5 minutes in LOAD mode.

10 Maintenance
10.14 Venting the machine (de-pressurising)
Fig. 30 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum oil level
1. CAUTION!
Danger of burning - hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.
2. Check the cooling oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

CAUTION
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

10 Maintenance
Fig. 31 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 Plug-in nozzle 8 Maintenance hose
Isolating the machine from the air system
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
Venting the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 bar.
The pressure gauge does not read 0 bar after automatic venting?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
the KAESER Service.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

10 Maintenance
10.15 Replenishing the cooling oil

Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

Fig. 32 Replenishing the cooling oil

1 Hose coupling (air cooler venting) 6 Plug-in nozzle
2 Pressure gauge 7 Shut-off valve
3 Hose coupling (oil separator tank venting) A Shut-off valve open
4 Oil filler port with plug B Shut-off valve closed
5 Cooling oil level indicator 8 Maintenance hose
1. Vent the machine as described in section 10.15.1.

2. Fill with cooling oil and test run as described in section 10.15.2.
10.15.1 Venting the machine (de-pressurising)

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
CAUTION
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

10 Maintenance
Isolating the machine from the air system
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
Venting the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 bar.
The pressure gauge does not read 0 bar after automatic venting?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
the KAESER Service.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/check valve.
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
10.15.2 Topping up with cooling oil and trial run

Replenishing the cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. WARNING!
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
2. NOTICE!
The machine could be damaged by unsuitable oil!
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
3. Slowly unscrew the filler plug 4 .
4. Top up to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.
Starting the machine and carrying out a trial run
1. Close all access doors, replace and secure all removable panels.

10 Maintenance
10.16 Changing the cooling oil
3. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.
4. Switch off the machine and check visually for leaks.

Drain the oil completely from the following components:
■ Oil separator tank
■ Oil cooler
■ Airend
■ Heat exchanger (Option 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 compres‐
sor itself or from an external source.
An external source of compressed air is necessary in the following cases (examples):

■ 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.
CAUTION
There is risk of burns from hot components and oil!
➤ Wear long-sleeved clothing and gloves.

10 Maintenance
Fig. 33 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 Plug-in nozzle 11 Shut-off valve (oil drain)
7 Shut-off valve
Oil change using the internal pressure Oil change with an external compressed air
source
The machine has been running at least 5 mi‐ The power supply isolating device is switched
nutes in LOAD mode. off,
The machine is fully vented, the device is locked off,
the pressure gauge on the oil separator tank the absence of any voltage has been verified.
reads 0 bar. The machine is fully vented,
1. Close the shut-off valve 10 in the venting the pressure gauge on the oil separator tank
line. reads 0 bar.
2. Select IDLE. An external source of compressed air is availa‐
ble.
3. Start the machine and watch the oil separa‐
tor tank pressure gauge 2 until it reads 3– 1. Close the shut-off valve 10 in the venting
5 bar. line.
4. Switch off and lock out the power supply 2. With the shut-off valve closed, insert the
disconnecting device and verify the absence male hose fitting 6 into the hose cou‐
of any voltage. pling 3.
5. Wait at least 2 minutes to allow the oil to 3. Connect the maintenance hose to the exter‐
flow back to the separator tank. nal air supply.
4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3–
5 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
Draining the oil from the separator tank
1. Have an oil receptacle ready.

10 Maintenance
3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Draining the oil from the cooler
Fig. 34 Changing the cooling oil, oil cooler

1 Oil cooler 6 Plug-in nozzle
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve

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

10 Maintenance
Draining the oil from the airend
Fig. 35 Changing the cooling oil, airend

1 Compressed air outlet, 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. 33) into the hose coupling 2 .
4. Open shut-off valves 3 and 7 (Fig. 33)
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.

10 Maintenance
Option W2/W3 Draining the oil from the heat exchanger
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. 33) in the hose coupling 1 .
4. Open the shut-off valves 3 and 7 (Fig. 33) and allow the oil to drain completely.
Filling with cooling oil
1. WARNING!
Compressed air!
2. Slowly open the filler plug 4 (Fig. 33).
3. Fill with cooling oil.
4. Check the filler plug and ring seal for damage and screw the plug back in again.
Starting the machine and performing a trial run
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
➤ Dispose of used oil in accordance with environment protection regulations.

10 Maintenance
10.17 Changing the oil filter cartridge
10.17 Changing the oil filter cartridge

Material Spares
Cleaning cloth

The machine is fully vented,
the pressure gauge on the oil separator tank reads 0 bar.
CAUTION
There is risk of burns from hot components and oil!
➤ Wear long-sleeved clothing and gloves.
Fig. 37 Changing the oil filter

1 Oil filter cartridge
2 Direction of rotation for opening the filter housing
Changing the oil filter cartridge
1. WARNING!
Compressed air!
2. Unscrew the cover of the filter housing.
3. Remove the old oil filter cartridge and dispose of according to environmental protection regula‐
tions.
4. Insert the new oil filter cartridge.
5. Ensure the correct torque when screwing the cover of the filter housing down.
The required torque is indicated on the cover.

10 Maintenance
10.18 Changing the oil separator cartridge
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and performing a trial run
4. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.

The oil separator element cannot be cleaned.
The life of the oil separator cartridge is influenced by:

■ contamination in the air drawn into the compressor,
■ and adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
─ Air filter
Material Spares
Cleaning cloth
Precondition The supply disconnecting device is switched off,

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

10 Maintenance
Fig. 38 Changing the oil separator cartridge

14 Cover 19 Self-locking nut
15 Dirt trap 20 Screw connection
16 Air pipe 21 Gasket
17 Fixing screw 23 Oil separator cartridge
Changing the oil separator cartridge
1. WARNING!
Compressed air!
2. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
3. Unscrew the nut 19 and turn the air pipe 16 to one side.
4. Remove the cover fixing screws 17 and carefully remove the cover 14 .
5. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac‐
cording to environmental protection regulations.
6. Clean all sealing faces.
7. Insert the new oil separator cartridge with gaskets and screw down the cover.
8. Renew the O-ring and strainer in the dirt trap 15 .
9. Attach the air pipe to the cover 14 with a new, self-locking nut.
10. Replace and tighten all fittings.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a trial run
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.

10 Maintenance
10.19 Cleaning the refrigerant condenser
10.19 Cleaning the refrigerant condenser

The refrigeration circuit is a closed system. Repairs may only be carried out by certified personnel.
Material Brush and vacuum cleaner

Face mask (as required)
Fig. 39 Refrigeration dryer

1 Refrigerant condenser
2 Brush
Do not use sharp objects to clean the refrigerant condenser. The refrigerant condenser could be
damaged.
Avoid creating clouds of dust.

➤ Dry brush the refrigerant condenser and use a vacuum cleaner to remove any dirt.
The refrigerant condenser can no longer be cleaned?
➤ Have stubborn clogging removed by an authorized KAESER Service Technician.
10.20 Maintaining the condensate drain

Condensate is drained at two locations via electronic condensate drains:
■ at the cyclone separator
■ at the condensate separator of the refrigeration dryer
10.20.1 Condensate drain check

The Power LED lights.

10 Maintenance
Fig. 40 Condensate drain check

1 Power LED
2 «TEST» key
3 Alarm LED
1. CAUTION!
Danger of burns from hot components near the condensate drain!
➤ Work with caution.
2. With one hand, lightly touch the condensate drain hose at the condensate drain.
3. With your other hand, push and hold the «TEST» key at the condensate drain for at least
2 seconds.
Result As soon as the condensate drain opens, you will feel a short burst at the condensate drain hose.
Replace the service unit if you do not experience a burst during manual test.
10.20.2 Changing the service unit

The condensate drain cannot be cleaned. The service unit must be changed if condensate does
not drain.
Precondition The power supply isolator is switched off (all poles),

the absence of voltage has been verified.
The Power LED is off (see Fig. 40).

10 Maintenance
Fig. 41 Changing the service unit

1 Service unit 6 Condensate drain hose fitting
2 Control module 7 Contact spring
3 Sensor 8 Condensate inlet
4 Sensor opening 9 Shut-off valve
5 Snap fastener
Removing the service unit
1. Close the shut-off valve 9 upstream of the condensate drain.

2. Unscrew the drain hose fitting.
3. Press the snap fastener 5 and remove the control module carefully from the service unit.
4. Carefully unscrew the Service Unit from the pipe at the condensate inlet.
Fitting the service unit
Use only KAESER Service Units to ensure correct function of the condensate drain.
Precondition Make sure the top of the service unit and the contact spring are clean and dry.
1. Screw the service unit to the inlet pipe.

2. Carefully insert the control module sensor 3 in the opening 4 in the new service unit.
3. Place the hook of the control module into the service module eye and press until the snap fas‐
tener can be heard to click into place.
4. Attach the condensate hose and open the shut-off valve 9 upstream of the condensate drain.

10 Maintenance
10.21 Documenting maintenance and service work
10.21 Documenting 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. 64 Logged maintenance tasks

11.1 Note the nameplate

11.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.
11.2 Ordering consumable parts and operating fluids/materials

KAESER consumable parts and operating materials are original KAESER products. They are spe‐
cifically selected for use in KAESER machines.
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 damage.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spares or operating fluids/materials.
➤ Use only original parts and operating fluids/materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.
Machine
Name Number
Air filter element 1250
Filter mat (control cabinet) 1100
Filter mat (Option K3) 1050
Oil filter 1200
Oil separator cartridge 1450
Cooling oil 1600
Condensate drain: 9602
Service-Unit
Bearing grease 100 g 9.0915.0
400 6.3234.0
Tab. 65 Consumable parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,

11.4 Service Addresses
■ The security of genuine KAESER spares.

■ Increased legal certainty as all regulations are kept to.
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.
11.4 Service Addresses

Addresses of KAESER agents are given at the end of this manual.
11.5 Replacement parts for service and repair

Use these parts lists to plan your material requirement according to operating conditions and to or‐
der the required spare parts.
➤ Make sure that any service or repair tasks not described in this manual are carried out by
an authorized KAESER Service Technician.







12.1 De-commissioning

12.1 De-commissioning
De-commissioning is necessary, for example, 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.
Temporary de-commissioning
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 protec‐
tion against corrosion.
Long-term de-commissioning
Precondition Immediately prior to de-commissioning, run the machine under LOAD for at least 30 minutes.
The power supply isolating device is switched off,
it is locked off,
a check has been made that no voltage is present on the machine.
The machine is fully vented.
1. Allow the machine to completely cool down.

2. Disconnect all air and electrical connections.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact
KAESER SERVICE for more information.
Material Desiccant
Plastic sheeting
Wooden crate
Precondition The machine is decommissioned.

The machine is dry and cooled down.
1. Place sufficient desiccant silica gel or desiccant clay) in the machine.

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.

12.4 Transport
The following measures also apply to machines not yet commissioned.

Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. NOTICE!
Moisture and frost can damage the machine!
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Mass and centre of gravity determine the most suitable method of transportation. The centre of
gravity is shown in the drawing in chapter 13.3.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only by forklift truck or lifting gear only by personnel trained in the safe transportation of
loads.
➤ Make sure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The whole machine is over the forks.
Fig. 42 Transporting with a forklift truck
➤ Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transport with a crane

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

■ Pipe sockets

12.5 Disposal
■ Flanges
■ attached components such as cyclone separators, condensate drains or filters
■ Rain protection covers
➤ Please consult with KAESER if you have questions to the appropriate lifting gear.
Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the enclosure.
Fig. 43 Transporting with a crane

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

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

➤ Refrigerant and oil must be drained and disposed of by an authorized specialist workshop.

12.5 Disposal
12.5.1 Dispose of the battery in accordance with local environmental regulations.

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be delivered to the
national battery collection system. This procedure facilitates the handling and recycling of batteries.
The 2006/66/EC directive stipulates for the EU member states that old batteries are returned to the
point of sale or delivered to a designated disposal system (free of charge). These disposal facilities
may be local recycling yards for used electric and electronic devices and their points of sale.
Fig. 44 Battery labelling

1 Do not dispose of batteries with residential waste.
2 Battery contains lead (if applicable)
➤ Comply with national disposal regulations and dispose of batteries in an environmentally-

friendly manner.
You actively contribute to the protection of our environment when you bring used bateries to
the appropriate recycling system.

13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram)
13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex
13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control
13.2 Option C1
Pipeline and instrument flow diagram (P&I diagram)
MODULATING control

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex
13.3 Dimensional drawing
13.3 Dimensional drawing

901713 05 E
960 K3
900 Outlet: cooling air Outlet: compressed air 214 565 848
K3
Inlet:
cooling air
595
13
13.3
1530
Inlet:
Inlet: ID G 1 1/4 intake air
Subject to development-related changes.

Drawing may be altered only via CAD.
cooling air
830
816
715
ID G 1/4
Annex
60
50 662 387 806 90 135 Connection: O 80
95
100
205
condensate drain

73 762 90 135
A
40 1630
Dimensional drawing
1770

H1 H1
843 574
95
100
740
O 9 ID G 1 W2 W3 986 387
430
O 110 90° Z
50 662
87
90°
10 250
View A
113
750
Z
58
100
286
O
100
60
638
36
910
36
400
350
130
26
90° 90° O
3x 100
Electrical connections (optional)
580
Electrical connections (optional)
ID : Internal thread
Change number Projection Scale Date Name
1:15 Drawn 10.09.2013 PFLAUM2
Document TZM Original Edited 21.10.2013 ROEBLITZ1 Language Sheet
W3 int. heat recovery ΔT=55K 10256220 E 00 A2 Released 22.10.2013 SCHUBT4 E 1/1

: Center of gravity
Position marginally dependent on design W2 int. heat recovery ΔT=25K Document TZD Designation
H1 Adjustable machine feet 10256220 D 00
ASD.3 T K1
K1 Air cooling Status Dimension and connection dim.
Transport opening ≥ machine width + 100mm Released
Drawings remain our exclusive property.

They are entrusted only for the agreed upon purpose.
Copies or any other reproduction, including storage, treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose.
Neither originals nor reproductions may be given to or made available to third parties.
Stand 17.10.2013
K3 Cooling air filter mats
117
118
K1 .
ASD 35/40 : V = 3.800m³/h
.
ASD 50 : V = 4.500m³/h Outlet: cooling air
.
ASD 60 : V = 5.400m³/h
848
565 538
35 Inlet:
13
cooling air
13.3
665
595
.
ASD 35 : V = 3.200m³/h
Subject to development-related changes.

Drawing may be altered only via CAD.
.
ASD 40 : V = 3.100m³/h
.
ASD 50 : V = 3.800m³/h
.
ASD 60 : V = 4.600m³/h
Annex
35
635

816
Dimensional drawing

max. drilling depth 15mm 843
574 533
35
350
35
143
13
O1 470 52
2
356
312
286
74
max. drilling depth 15mm 612
644
Change number Projection Scale Date Name
1:15 Drawn 15.10.2013 ROEBLITZ1
Document TZM Original Edited 14.11.2013 ROEBLITZ1 Language Sheet
10258390 E 00 A3 Released 14.11.2013 SCHUBT4 E 1/1
Total permissible pressure loss for installed ducting
Document TZD Designation
without filter with filtermats
10258390 D 00
ASD.3 K1
ASD 35/40/50 ∆ p max . 60 Pa (6 mm water column) 30 Pa (3 mm water column)
Status Connection, dp cool. air duct
ASD 60 ∆ p max . 40 Pa (4 mm water column) 20 Pa (2 mm water column) Released
Drawings remain our exclusive property.

They are entrusted only for the agreed upon purpose.
Copies or any other reproduction, including storage, treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose.
Neither originals nor reproductions may be given to or made available to third parties.
Stand 17.10.2013
K1 Air cooling
901713 05 E
13 Annex
13.4 Electrical Diagram

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex


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Operating Manual

ASD T SIGMA CONTROL 2

1 Regarding this document

Operating Manual Screw Compressor

4.2 Machine function .............................................................................................................. 30

Operating Manual Screw Compressor

9 Fault Recognition and Rectification

Operating Manual Screw Compressor

Operating Manual Screw Compressor

Fig. 1 Maximum relative humidity of inlet air ........................................................................................ 6

Operating Manual Screw Compressor

Operating Manual Screw Compressor

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Operating Manual Screw Compressor

Tab. 55 MODULATING control: Setting the shut-off valve ...................................................................... 54

Operating Manual Screw Compressor

1 Regarding this document

1.2 Further documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

Tab. 1 Danger levels and their definition (personal injury)

Operating Manual Screw Compressor

1.4.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

Operating Manual Screw Compressor

Further information Further subjects are introduced here.

Operating Manual Screw Compressor

The nameplate is located on the outside of the machine:

➤ Enter here the nameplate data as a reference:

Option Option code Available?

Operating Manual Screw Compressor

ASD 35 ASD 40 ASD 50 ASD 60

2.5 Ambient conditions

Tab. 7 Ambient conditions

Operating Manual Screw Compressor

Fig. 1 Maximum relative humidity of inlet air

Ventilation at 50 Hz mains frequency:

ASD 35 ASD 40 ASD 50 ASD 60

Tab. 8 Overview Ventilation (50Hz)

Ventilation at 60 Hz mains frequency:

ASD 35 ASD 40 ASD 50 ASD 60

Tab. 9 Overview Ventilation (60Hz)

Operating Manual Screw Compressor

Pressure relief valve activating pressure at 50 Hz [bar]:

Maximum working over‐ ASD 35 ASD 40 ASD 50 ASD 60

Tab. 10 Pressure relief valve activating pressure (50Hz)

Pressure relief valve activating pressure at 60 Hz [bar]:

Maximum working over‐ ASD 35 ASD 40 ASD 50 ASD 60

Tab. 11 Pressure relief valve activating pressure (60Hz)

2.8 Flow rate (constant delivery volume relative to intake conditions)

Max. working pres‐ ASD 35 ASD 40 ASD 50 ASD 60

Tab. 12 Flow rate (50Hz)

Flow rate [m3/min] at 60 Hz mains frequency:

Max. working pres‐ ASD 35 ASD 40 ASD 50 ASD 60

Tab. 13 Flow rate (60 Hz)

Operating Manual Screw Compressor