Service Manual: Screw Compressor Asd SFC

Service Manual
Screw Compressor
ASD SFC
9_5714 06 E
Manufacturer:
KAESER KOMPRESSOREN GmbH

96450 Coburg PO Box 2143 GERMANY Tel. +49-(0)9561-6400 Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SASD 1.00 en
Contents
9_5714 06 E
Regarding this document

1.1 Using the Document .........................................................................................................
1.2 Additional Documents ......................................................................................................
1.3 Copyright ..........................................................................................................................
1.4 Symbols and Identification ...............................................................................................
1.4.1
Warnings .............................................................................................................
1.4.2
Other instructions and symbols ..........................................................................
1
1
1
1
1
2
Technical Specification
2.1 Nameplate ........................................................................................................................
2.2 Options .............................................................................................................................
2.3 Weight ..............................................................................................................................
2.4 Temperature .....................................................................................................................
2.5 Ambient Conditions ..........................................................................................................
2.6 Ventilation ........................................................................................................................
2.7 Pressure ...........................................................................................................................
2.8 Delivery ............................................................................................................................
2.8.1
Rated power supply 400V5%/3/50Hz ...............................................................
2.8.2
Rated power supply 380V 5%, 3-ph, 60Hz .......................................................
2.8.3
Rated power supply 460V 5%, 3-ph, 60Hz .......................................................
2.9 Cooling Oil Recommendation ..........................................................................................
2.10 Cooling Oil Charge ...........................................................................................................
2.11 Motors and Power ............................................................................................................
2.11.1 Drive motor .........................................................................................................
2.11.2 Fan motor ...........................................................................................................
2.12 Sound Pressure Level ......................................................................................................
2.13 Power Supply ...................................................................................................................
2.14 Power supply specifications .............................................................................................
2.14.1 Mains frequency: 50 Hz ......................................................................................
2.14.2 Mains frequency: 60 Hz ......................................................................................
3
3
3
4
4
5
5
6
7
8
9
10
10
11
11
12
12
12
13
13
14
Safety and Responsibility

3.1 Basic Information .............................................................................................................
3.2 Specified Use ...................................................................................................................
3.3 Improper Use ...................................................................................................................
3.4 User's Responsibilities .....................................................................................................
3.4.1
Observe statutory and universally accepted regulations ....................................
3.4.2
Qualified personnel .............................................................................................
3.4.3
Inspection Schedules and Accident Prevention Regulations .............................
3.5 Dangers ............................................................................................................................
3.5.1
Safely Dealing with Sources of Danger ..............................................................
3.5.2
Safe Machine Operation .....................................................................................
3.5.3
Organisational Measures ....................................................................................
3.5.4
Danger Areas ......................................................................................................
3.6 Safety Devices .................................................................................................................
3.7 Safety Signs .....................................................................................................................
3.8 In Emergency ...................................................................................................................
3.8.1
Fire fighting .........................................................................................................
3.8.2
Remove any cooling oil from your person. .........................................................
3.9 Warranty ...........................................................................................................................
3.10 Environmental Protection .................................................................................................
15
15
15
15
15
16
16
17
17
19
20
20
20
21
22
22
22
22
23
Design and Function

4.1 Outline of the Machine .....................................................................................................
4.2 Functional Description ......................................................................................................
4.2.1
Frequency Converter ..........................................................................................
24
24
25
Service Manual Screw Compressor

ASD SFC
Contents
4.2.2
Floating relay contacts ........................................................................................
Options .............................................................................................................................
4.3.1
Machine mountings .............................................................................................
4.3.2
Optional Filter Monitoring Set .............................................................................
4.3.3
Cooling air filter mat ............................................................................................
4.3.4
Heat Recovery ....................................................................................................
Operating Modes and Control Modes ..............................................................................
4.4.1
Operating modes ................................................................................................
4.4.2
Control modes ....................................................................................................
4.4.3
Frequency-Controlled Drive (SFC) .....................................................................
Safety Devices .................................................................................................................
SIGMA CONTROL Keys and Indicators ..........................................................................
26
26
26
26
26
27
27
27
27
28
29
29
Installation and Operating Conditions

5.1 Safety ...............................................................................................................................
5.2 Installation Conditions ......................................................................................................
5.2.1
Place of installation and distances ......................................................................
5.2.2
Ensure adequate ventilation. ..............................................................................
5.2.3
Exhaust duct design ...........................................................................................
5.3 Operating the Machine in an Air System. .........................................................................
32
32
32
33
33
34
Installation
6.1 Safety ...............................................................................................................................
6.2 Reporting Transport Damage ...........................................................................................
6.3 Making the Compressed Air Connection ..........................................................................
6.4 Connecting the Power Supply ..........................................................................................
6.5 Connecting the External Pressure Transducer ................................................................
6.6 Options .............................................................................................................................
6.6.1
nchoring the machine .......................................................................................
6.6.2
Connecting the Heat Recovery System ..............................................................
35
35
35
36
37
37
37
37
Initial Start-up
7.1 Safety ...............................................................................................................................
7.2 Instructions to be Observed before Every Commissioning or Re-commissioning ...........
7.3 Checking Installation and Operating Conditions ..............................................................
7.4 Commissioning the Frequency Converter ........................................................................
7.5 Setting the Motor Overload Protection Switch .................................................................
7.6 Pouring Cooling Oil into the Airend ..................................................................................
7.7 Checking Direction of Rotation .........................................................................................
7.8 Starting the Machine for the First Time ............................................................................
7.9 Setting the Setpoint Pressure ..........................................................................................
7.10 Changing the display language ........................................................................................
39
39
40
41
41
41
42
42
43
43
Operation
8.1 Switching On and Off .......................................................................................................
8.1.1
Switching on .......................................................................................................
8.1.2
Shutdown ............................................................................................................
8.2 Switching Off in an Emergency and Switching On again .................................................
8.3 Acknowledging Alarm and Warning Messages ................................................................
8.4 Remote On and Off Switching ..........................................................................................
8.5 Switching On and Off with the Clock ................................................................................
45
45
45
46
46
47
48
Fault Recognition and Rectification

9.1 Basic Information .............................................................................................................
9.2 Alarm Messages (machine shutdown) .............................................................................
9.3 Warning Messages (yellow LED lights) ............................................................................
9.4 Other Faults .....................................................................................................................
50
50
53
57
4.3
4.4
4.5
4.6
ii

ASD SFC
9_5714 06 E
Contents
9_5714 06 E
10
Maintenance
10.1 Safety ...............................................................................................................................
10.2 Maintenance Schedule .....................................................................................................
10.2.1 Logging maintenance work .................................................................................
10.2.2 Resetting maintenance interval counters ............................................................
10.2.3 Regular Maintenance Tasks ...............................................................................
10.2.4 Cooling Oil: Change Interval ...............................................................................
10.2.5 Regular service work ..........................................................................................
10.3 Cooler: Cleaning or Renewing the Filter Mats .................................................................
10.4 Control Cabinet: Clean or Replace the Filter Mat. ...........................................................
10.5 Cooler Maintenance .........................................................................................................
10.6 Heat Recovery System Maintenance ...............................................................................
10.6.1 External heat recovery ........................................................................................
10.6.2 Internal heat recovery .........................................................................................
10.7 Air Filter Maintenance ......................................................................................................
10.8 Motor Maintenance ..........................................................................................................
10.9 Checking the Coupling .....................................................................................................
10.10 Checking the Pressure Relief Valve .................................................................................
10.11 Checking the Excess Temperature Safety Shutdown Function .......................................
10.12 Checking the Cooling Oil Level ........................................................................................
10.13 Venting the Machine (depressurizing) ..............................................................................
10.14 Topping up the Cooling Oil ...............................................................................................
10.14.1 Venting the machine (depressurizing) ................................................................
10.14.2 Topping up with cooling oil and trial run .............................................................
10.15 Changing the Cooling Oil .................................................................................................
10.16 Changing the Oil Filter .....................................................................................................
10.17 Changing the Oil Separator Cartridge ..............................................................................
10.18 Document maintenance and service work. ......................................................................
58
59
59
59
59
60
61
61
62
63
64
64
65
65
66
66
67
68
68
69
71
71
72
73
77
78
81
11
Spares, Operating Materials, Service

11.1 Note the Nameplate .........................................................................................................
11.2 Ordering Consumable Parts and Operating Materials .....................................................
11.3 SIGMA AIR SERVICE ......................................................................................................
11.4 Service Addresses ...........................................................................................................
11.5 Spare Parts for Service and Repair .................................................................................
82
82
82
83
83
12
Decommissioning, Storage and Transport

12.1 Putting Out of Operation ..................................................................................................
12.2 Packing ............................................................................................................................
12.3 Storage .............................................................................................................................
12.4 Transporting .....................................................................................................................
12.4.1 Safety ..................................................................................................................
12.4.2 Transporting with a forklift truck ..........................................................................
12.4.3 Transporting with a crane ...................................................................................
12.5 Disposal ...........................................................................................................................
86
86
86
87
87
87
87
88
13
Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) .......................................................
13.2 Dimensional Drawing .......................................................................................................
13.3 Electrical Diagram ............................................................................................................
89
95
98

ASD SFC
iii
Contents
iv

ASD SFC
9_5714 06 E
List of Illustrations
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
9_5714 06 E
Maximum relative humidity .........................................................................................................

Delivery and control range .........................................................................................................
Location of safety signs ..............................................................................................................
Enclosure ...................................................................................................................................
Machine layout ...........................................................................................................................
Machine mountings ....................................................................................................................
Cooling air filter mat (option K3) .................................................................................................
Internal heat recovery (option W2/W3) .......................................................................................
Keys ...........................................................................................................................................
Indicators ....................................................................................................................................
Recommended installation and dimensions [mm] ......................................................................
Compressed air connection ........................................................................................................
Connecting the heat recovery system ........................................................................................
Inlet valve filling port ...................................................................................................................
Coupling .....................................................................................................................................
Label: Changing the display language .......................................................................................
Switching on and off ...................................................................................................................
Switching off in an emergency ...................................................................................................
Acknowledging/resetting messages ...........................................................................................
Switching on and off in remote ...................................................................................................
Switching on and off with the clock ............................................................................................
Filter mat for the air and oil cooler ..............................................................................................
Control cabinet ventilation grill ...................................................................................................
Cleaning the cooler ....................................................................................................................
Air filter maintenance ..................................................................................................................
Checking the coupling ................................................................................................................
Checking the cooling oil level .....................................................................................................
Venting the machine ...................................................................................................................
Topping up the Cooling Oil .........................................................................................................
Changing the cooling oil, oil separator tank ...............................................................................
Changing the cooling oil, oil cooler .............................................................................................
Changing the cooling oil, airend .................................................................................................
Changing the cooling oil, heat recovery system .........................................................................
Changing the oil filter ..................................................................................................................
Changing the oil separator cartridge ..........................................................................................
Transporting with a forklift truck .................................................................................................
Transporting with a crane ...........................................................................................................

ASD SFC
5
6
21
24
25
26
26
27
29
30
33
36
38
41
42
44
45
46
47
48
49
62
63
64
65
67
69
70
71
74
75
76
77
78
79
87
88
vi

ASD SFC
9_5714 06 E
List of Tables
Tab. 1
Tab. 2
Tab. 3
Tab. 4
Tab. 5
Tab. 6
Tab. 7
Tab. 8
Tab. 9
Tab. 10
Tab. 11
Tab. 12
Tab. 13
Tab. 14
Tab. 15
Tab. 16
Tab. 17
Tab. 18
Tab. 19
Tab. 20
Tab. 21
Tab. 22
Tab. 23
Tab. 24
Tab. 25
Tab. 26
Tab. 27
Tab. 28
Tab. 29
Tab. 30
Tab. 31
Tab. 32
Tab. 33
Tab. 34
Tab. 35
Tab. 36
Tab. 37
Tab. 38
Tab. 39
Tab. 40
Tab. 41
Tab. 42
Tab. 43
Tab. 44
Tab. 45
Tab. 46
Tab. 47
Tab. 48
Tab. 49
Tab. 50
Tab. 51
9_5714 06 E
The levels of danger and their meaning .....................................................................................

Nameplate ..................................................................................................................................
Options .......................................................................................................................................
Machine weight ..........................................................................................................................
Temperature ...............................................................................................................................
Ambient Conditions ....................................................................................................................
Ventilation ...................................................................................................................................
Pressure relief valve activating pressure (50 Hz) .......................................................................
Pressure relief valve activating pressure (60Hz) ........................................................................
Delivery 400 V / 8.5 bar ..............................................................................................................
Delivery 400 V / 10.0 bar ............................................................................................................
Delivery 400 V / 11.0 bar ............................................................................................................
Delivery 400 V / 15.0 bar ............................................................................................................
Delivery 380 V / 8.5 bar ..............................................................................................................
Delivery 380 V / 10.0 bar ............................................................................................................
Delivery 380 V / 12.0 bar ............................................................................................................
Delivery 380 V / 15.0 bar ............................................................................................................
Delivery 460 V / 10 bar ...............................................................................................................
Delivery 460 V / 15.0 bar ............................................................................................................
Cooling Oil Recommendation .....................................................................................................
Cooling Oil Charge .....................................................................................................................
Cooling oil charge (option W1) ...................................................................................................
Drive motor .................................................................................................................................
Drive motor rated speed (50 Hz) ................................................................................................
Drive motor rated speed (60Hz) .................................................................................................
Fan motor ..................................................................................................................................
Sound Pressure Level ................................................................................................................
Connection details 400V/3/50Hz ................................................................................................
Inspection intervals according to Ordinance on Industrial Safety and Health ............................
Danger Areas .............................................................................................................................
Safety Signs ...............................................................................................................................
Keys ...........................................................................................................................................
Indicators ....................................................................................................................................
Re-commissioning after storage .................................................................................................
Installation conditions checklist ..................................................................................................
Machine identification .................................................................................................................
Remote control identification ......................................................................................................
Machine identification .................................................................................................................
Alarm messages and measures .................................................................................................
Warning messages .....................................................................................................................
Other faults and actions .............................................................................................................
Regular maintenance tasks ........................................................................................................
Cooling oil changing intervals .....................................................................................................
Regular service work ..................................................................................................................
Logged maintenance tasks ........................................................................................................
Consumable parts ......................................................................................................................
Consumable parts for the frequency converter ..........................................................................
2
3
3
4
4
4
5
5
6
7
7
7
7
8
8
8
9
9
9
10
10
11
11
11
11
11
12
12
12
13
14
14
17
20
21
29
30
40
40
48
48
49
50
53
57
60
61
61
81
82
82

ASD SFC
vii
viii

ASD SFC
9_5714 06 E
1.1
Using the Document
1 Regarding this document

1.1
Using the Document

The service manual is part of the machine. It describes the machine as it was at the time of first
delivery after manufacture.
Keep the service manual in a safe place throughout the life of the machine.
Pass the manual on to the next owner/user of the machine.
Ensure that all amendments received are entered in the manual.
Enter details from the machine nameplate and individual items of equipment in the table in chap
ter 2.
1.2
Additional Documents
Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
Certificate of acceptance / operating instructions for the pressure vessel.
Manufacturer's declaration / declaration of conformity in accordance with applicable directives.
Missing documents can be requested from KAESER.

Make sure all documents are complete and observe the instructions contained in them.
Make sure you give the data from the nameplate when ordering documents.
1.3
Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documentation
should be referred to KAESER. Correct use of information will be fully supported.
1.4
1.4.1
Symbols and Identification

Warnings
Warning notices indicate three levels of danger signified by the signal word.
DANGER
WARNING
CAUTION
DANGER
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruction.
The measures required to protect yourself from danger are shown here.
9_5714 06 E

ASD SFC
1.4
Symbols and Identification
Always read and comply with warning instructions.

Signal word Meaning
Consequences of non-observance
DANGER
Death or serious injury may result
Warns of an imminent threat of danger
WARNING Warns of possible danger

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

This symbol refers to particularly important information.
Material
Precondition
Here you will find details on special tools, operating materials or spare parts.
Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
Option H1
This bullet is is placed by lists of actions comprising one stage of a task.

In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used in
this service manual are explained in chapter 2.2 .
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
... and a remedy given.
This symbol refers to important information or measures concerning environmental protection.
Further information
Here, your attention is drawn to further topics.

ASD SFC
9_5714 06 E
2.1
Nameplate
2 Technical Specification
2.1
Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine:
above the cooler,

or
on the rear of the machine.
Enter the data from the nameplate here as a reference:

Attribute
Data
Model
Material no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature
Tab. 2
Nameplate
2.2
Options
The table contains a list of possible options.
Enter options here as a reference:
Option
Tab. 3
2.3
Option code
Filter monitoring option package
C2
Machine mountings
H1
Air-cooling
K1
Cooling-air filter mat
K3
Transformer power supply
T2
Prepared for heat recovery
W1
Heat recovery T=25 K
W2
Heat recovery T=55 K
W3
Exists?
Options
Weight
The weight given is the maximum. The actual weights of individual machines are dependent on
equipment fitted.
9_5714 06 E

ASD SFC
2.4
Temperature
ASD 32
ASD 37
ASD 47
ASD 57
735
815
825
ASD 32
ASD 37
ASD 47
ASD 57
Minimum cut-in tempera

ture [C]
Typical airend discharge

temperature during opera
tion [C]
75100
75100
75100
Maximum airend dis

charge temperature (auto
matic safety shut-down)
[C]
110
110
110
ASD 32
ASD 37
ASD 47
ASD 57
Maximum altitude AMSL*

[m]
1000
1000
1000
Permissible ambient tem

perature [C]
345
345
345
Cooling air temperature

[C]
345
345
345
Inlet air temperature [C]
345
345
345
Maximum relative humidi

ty of inlet air
see figure 1
see figure 1
see figure 1
see figure 1
Weight [kg]
Tab. 4
2.4
Tab. 5
2.5
Machine weight
Temperature
Temperature
Ambient Conditions
* Higher altitudes are permissible only after consultation with the manufacturer
Tab. 6
Ambient Conditions

ASD SFC
9_5714 06 E
Fig. 1
2.6
Ventilation
Maximum relative humidity

T
H
2.6
Inlet air temperature [C]

Maximum relative humidity of inlet air [%]
Ventilation
The values given are minimum guide values.
Inlet aperture Z see fig

ure 11 [m2]
Forced ventilation with ex
haust fan:
Flow rate [m3/h] at 100 Pa
Exhaust duct:
Dimensions [mm]
Tab. 7
2.7
ASD 32
ASD 37
ASD 47
ASD 57
0.5
0.6
0.7
7230
8230
10230
650 x 650
650 x 650
650 x 650
Ventilation
Pressure
Maximum working pressure: see nameplate
Pressure relief valve activating pressure at 50 Hz [bar]
Maximum working pres
sure [bar]
Tab. 8
9_5714 06 E
ASD 32
ASD 37
ASD 47
ASD 57
8.5
10
10
10
10
14
14
14
11
14
14
14
15
16
16
16
Pressure relief valve activating pressure (50 Hz)

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

sure [bar]
Tab. 9
2.8
ASD 32
ASD 37
ASD 47
ASD 57
8.5
10
10
10
10
14
14
14
12
14
14
14
15
16
16
16
Pressure relief valve activating pressure (60Hz)
Delivery
Figure shows the delivery control range 1 in relation to the pressure SETPOINT 5 .
Fig. 2
Delivery and control range

1
2
V
Delivery
Vmax
Maximum air delivery at pressure
SETPOINT p1
Vmin
Minimum air delivery at pressure
SETPOINT p1
p1min
Minimum pressure SETPOINT setting (pa
rameter-dependent)
p1
Pressure SETPOINT setting

ASD SFC
7
8
9
p1max
Maximum possible SETPOINT pressure set
ting
p
Pressure SETPOINT
Vmin(p1)
Minimum air delivery (dependent on p1)
Vmax(p1)
Maximum air delivery (dependent on p1)
9_5714 06 E
2.8.1
2.8
Delivery
Rated power supply 400V5%/3/50Hz

Delivery V [m3/min] at maximum working pressure of 8.5 bar:
p1 [bar]
ASD 32
Vmin
Tab. 10
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.83
4.34
1.09
5.25
6,0
0.83
4.34
1.09
5.25
7,5
0.82
4.05
1.07
4.92
8.5 (p1max)
0.81
3.86
1.06
4.71
Delivery 400 V / 8.5 bar

p1 [bar]
ASD 32
Vmin
Tab. 11
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.71
3.55
8,5
0.71
3.55
7,5
0.69
3.30
8,5
0.68
3.10
9,0
0.67
2.98
10.0 (p1max)
0.90
2.86

p1 [bar]
ASD 32
Vmin
Tab. 12
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.80
4.27
9,0
0.80
4.27
10,0
0.79
4.12
11.0 (p1max)
0.78
3.90

p1 [bar]
ASD 32
Vmin
9_5714 06 E
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.63
3.65
0.62
3.70
9,0
0.63
3.65
10,0
0.61
3.55
11,0
0.59
3.40

ASD SFC
2.8
Delivery
p1 [bar]
ASD 32
Vmin
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
12,0
0.57
3.26
0.62
3.70
13,0
0.56
3.17
0.60
3.60
14,0
0.82
2.95
0.58
3.43
15.0 (p1max)
0.81
2.83
0.56
3.23
Tab. 13
2.8.2
Rated power supply 380V 5%, 3-ph, 60Hz

p1 [bar]
ASD 32
Vmin
Tab. 14
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
1.09
5.40
6,0
1.09
5.40
7,5
1.07
4.92
8.5 (p1max)
1.06
4.66

p1 [bar]
ASD 32
Vmin
Tab. 15
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.68
3.65
6,0
0.68
3.65
7,5
0.67
3.45
8,5
0.64
3.28
9,0
0.63
3.17
10.0 (p1max)
0.61
3.05

p1 [bar]
ASD 32
Vmin
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.80
4.20
9,0
0.80
4.20
10,0
0.76
4.05
11,0
0.73
3.85

ASD SFC
9_5714 06 E
2.8
Delivery
p1 [bar]
ASD 32
Vmin
12.0 (p1max)
Tab. 16
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
0.71
3.69

p1 [bar]
ASD 32
Vmin
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.53
3.48
13,0
0.53
3.48
14,0
0.52
3.31
15.0 (p1max)
0.51
3.15
Tab. 17
2.8.3
Rated power supply 460V 5%, 3-ph, 60Hz

Delivery V [m3/min] at maximum working pressure of 10 bar:
p1 [bar]
ASD 32
Vmin
Tab. 18
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.68
3.95
0.82
4.74
1.09
5.84
6,0
0.68
3.95
0.82
4.74
1.09
5.84
7,5
0.67
3.64
0.81
4.48
1.07
5.75
8,5
0.64
3.55
0.81
4.21
1.06
5.50
9,0
0.63
3.44
0.80
4.08
1.04
5.43
10 (p1max)
0.61
3.28
0.79
3.93
1.02
5.10
Delivery 460 V / 10 bar

p1 [bar]
ASD 32
Vmin
Tab. 19
9_5714 06 E
ASD 37
ASD 47
Vmax
Vmin
Vmax
Vmin
Vmax
p1min
0.56
3.74
0.73
4.52
11,0
0.56
3.74
0.73
4.52
12,0
0.54
3.57
0.71
4.36
13,0
0.53
3.38
0.69
4.14
14,0
0.82
3.18
0.66
4.00
15.0 (p1max)
0.81
3.06
0.99
3.82

ASD SFC
2.9
2.9
Cooling Oil Recommendation

A sticker showing the type of oil used is located near the oil separator tank filler.
Information on ordering cooling oil is found in chapter 11.
SIGMA FLUID
S460
MOL
FG460/FG680
Description
Silicone-free
synthetic oil
Mineral oil
Synthetic oil
Application
Standard oil for all applica Standard oil for all

tions except in connection applications except
with foodstuffs.
in connection with
Particularly suitable for ma foodstuffs.
Specifically for applications

where the compressed air
comes into contact with food
stuffs.
Approval
USDA H1, NSF

Approved for the manufac
ture of foodstuff packaging,
meat and poultry processing
and other food processing.
Viscosity at 40 C
45 mm2/s
(D 445; ASTM Test)
44 mm2/s
(DIN 515621)
50.7/70.0 mm2/s
(D 445; ASTM Test)
Viscosity at
100 C
7.2 mm2/s
(D 445; ASTM Test)
6.8 mm2/s
(DIN 515621)
8.2/710.4 mm2/s
(D 445; ASTM Test)
Flash point
238 C
(D 92; ASTM Test)
220 C
(ISO 2592)
245 C
(D 92; ASTM Test)
Density at 15 C
864 kg/m3
(ISO 12185)
Pour point
46 C
(D 97; ASTM Test)
33 C
(ISO 3016)
Demulsibility at
54 C
40/40/0/10 min
(D 1401; ASTM Test)
chines with a high duty cy Particularly suitable

cle.
for machines with a
low duty cycle.
Tab. 20
2.10
Cooling Oil Charge
Option K1
Tab. 21
10
Air-cooling
ASD 32
ASD 37
ASD 47
ASD 57
Total charge [l]
16
16
16
Top-up quantity [l]

(minimummaximum)
Cooling Oil Charge

ASD SFC
9_5714 06 E
Option W1/W2/W3
2.11
Motors and Power
Heat Recovery
The charge of cooling oil for machines with heat recovery is increased by the volume of oil in
the heat exchanger and connecting lines.
ASD 32
Option W1
ASD 37
ASD 47
ASD 57
Additional charge volume

[l]*
* Enter the volume required by your heat recovery system.
Tab. 22
Cooling oil charge (option W1)
ASD 32
ASD 37
ASD 47
ASD 57
1.1
1.7
1.7
ASD 32
ASD 37
ASD 47
ASD 57
1.1
1.7
1.7
ASD 32
ASD 37
ASD 47
ASD 57
Rated power [kW]
18.5
22.0
25.0
Enclosure protection
IP 55
IP 55
IP 55
ASD 32
ASD 37
ASD 47
ASD 57
8.5
2945
2945
10
2940
11
2945
15
2945
2945
Option W2
[l]
Tab. 23
Option W3
[l]
Tab. 24
2.11
Motors and Power
2.11.1
Tab. 25
Drive motor
Drive motor
Rated speed at 50 Hz [rpm]
sure [bar]
Tab. 26
9_5714 06 E
Drive motor rated speed (50 Hz)

ASD SFC
11
2.12
Sound Pressure Level
Rated speed at 60 Hz [rpm]

sure [bar]
Tab. 27
2.11.2
ASD 32
ASD 37
ASD 47
ASD 57
8.5
3550
10
3550
3545
3550
12
3550
15
1780
1780
3550
ASD 32
ASD 37
ASD 47
ASD 57
Rated power [kW]
0.30/0.50*
0.30/0.50*
0.40/0.50*
/*
Rated speed [rpm]
910
1080*
910
1080*
910
1080*
Enclosure protection
IP 54
IP 54
IP 54
Drive motor rated speed (60Hz)
Fan motor
* 60Hz
Tab. 28
Fan motor
2.12

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

(A)]
ASD 32
ASD 37
ASD 47
ASD 57
at 50 Hz
67
68
68
at 60 Hz
68
69
69
Tab. 29
2.13
Power Supply
Basic requirements
The machine is designed for a power supply conforming to EN 602041 (IEC 602041), section 4.3.
In the absence of other user-specified conditions, the limits laid down in this standard must be adhered
to.
It is recommended that the supplier and user confer and agree on the basis of the EN 602401, Annex
B.
12

ASD SFC
9_5714 06 E
2.14
Power supply specifications
The machine requires a symmetrical three-phase power supply.

In a symmetrical three-phase supply the phase angles and voltages are all the same.
The machine may only be operated from an earthed TN or TT three-phase supply.
Connection to an IT supply is not permitted without taking further measures (earth leak detection,
etc.).
Further requirements
Demands on a three-phase supply for a machine with the following equipment:
Variable frequency drive (SFC)
Refrigeration dryer powered from a transformer
This machine may only be supplied from an earthed TN or TT three-phase supply in which the neutral
point is earthed.
The machine may not be connected to a three-phase supply in which one of the phases is earthed,
as this can lead to dangerous voltage surges.
Connection to an IT supply is not permitted without further measures being taken (earth leak detection,
specially designed frequency converter, etc.).
Further information
2.14
The electrical diagram in chapter 13.3 contains further details of the power supply connection.

The following supply cable conductor cross sections (copper multicore) and fusing (slow-blow
class gL) are selected according to German DIN VDE 0100430 (IEC 60364443 and
IEC 603644473) and DIN VDE 0298-4 standards for 30 C ambient temperature and wiring
type C.
Electrical connection data, in some cases, depends the maximum working pressure of the ma
chine. These are shown in brackets().
The conductor cross-sections should be changed accordingly if other conditions prevail.
Other conditions would include:
2.14.1
higher temperature
other cable laying methods
cable lengths >50 m
Mains frequency: 50 Hz
Rated power supply: 400V5%/3/50Hz
ASD 32
ASD 37
ASD 47
ASD 57
50
63
80
4x10
4x16
4x25
43
54
66
Mains fusing [A]

Supply cable [mm2]
Current drawn [A]
Tab. 30
9_5714 06 E
Connection details 400V/3/50Hz

ASD SFC
13
2.14.2
2.14
Mains frequency: 60 Hz
Tab. 31
ASD 32
ASD 37
ASD 47
ASD 57
Mains fusing [A]
63
80
Supply cable [mm2]
4x16
4x25
Current drawn [A]
54
67
ASD 32
ASD 37
ASD 47
ASD 57
50
63
80
4x10
4x16
4x25
35
44
55

Mains fusing [A]

Supply cable [mm2]
Current drawn [A]
Tab. 32
14

ASD SFC
9_5714 06 E
3.1
Basic Information
3 Safety and Responsibility

3.1
Basic Information
The machine is manufactured to the latest engineering standards and acknowledged safety regula
tions. Nevertheless, dangers can arise through its operation:
Danger to life and limb of the operator or third parties.
Impairments to the machine and other material assets.
DANGER
Disregard of these instructions can result in serious injury.
Read the service manual carefully and take notice of the contents for safe machine operation.
Use this machine only if it is in a technically perfect condition and only for the purpose for which
it is intended; observe all safety measures and the instructions in the service manual.
Immediately rectify (have rectified) any faults that could be detrimental to safety.
3.2
Specified Use
The machine is intended solely for industrial use in generating compressed air. Any other use is
incorrect and does not comply with requirements. The manufacturer is not liable for any resulting
damages. The risk involved in such incorrect use is taken solely by the user.
Keep to the specifications listed in this service manual.
Operate the machine only within its performance limits and under the permitted ambient condi
tions.
Do not use compressed air for breathing purposes unless it is specifically treated for such.
Do not use compressed for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated for this.
3.3
Improper Use
Never direct compressed air at persons or animals.
Cooling air, warmed after passing through the machine, may be used for heating purposes but
only when it poses no health risk to humans or animals. If necessary, hot cooling air should be
treated by suitable means.
Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
Do not operate the machine in areas in which specific requirements with regard to explosion
protection are applied.
3.4
3.4.1
User's Responsibilities
Observe statutory and universally accepted regulations
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
Observe relevant statutory and accepted regulations during installation, operation and mainte
nance of the machine.
9_5714 06 E

ASD SFC
15
3.4.2
3.4
User's Responsibilities
Qualified personnel
These are people who, by virtue of their training, knowledge and experience as well as their knowl
edge of relevant regulations can assess the work to be done and recognise the possible dangers
involved.
Authorised operators possess the following qualifications:
are of legal age,
are conversant with and adhere to the safety instructions and sections of the service manual
relevant to operation,
have received adequate training and authorisation to operate electrical and compressed air de
vices.
Additional qualifications for compressors with refrigeration dryers:
Adequate training and authorisation ton refrigeration devices.
Authorised installation and maintenance personnel have the following qualifications:
are of legal age,
have read, are conversant with and adhere to the safety instructions and sections of the service
manual applicable to installation and maintenance,
are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
are able to recognise the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
have received adequate training and authorisation for the safe installation and maintenance on
this equipment.
Additional qualifications for compressors with refrigeration dryers:
fully conversant with the safety concepts and regulations concerning refrigeration devices,
must be able to recognise the possible dangers of refrigeration devices and take appropriate
measures to safeguard persons and property.
Ensure that operating, installation and maintenance personnel are qualified and authorised to
carry out their tasks.
3.4.3
Inspection Schedules and Accident Prevention Regulations

The machine is subject to local inspection schedules.
Examples German inspection schedules
Carry out recurring inspections to BGR 500, chapter 2.11:
The user must ensure that the machine's safety devices are checked for function as required or
at least annually.
Carry out oil changes to BGR 500, chapter 2.11.
The user must ensure that the compressor oil is changed as required or at least annually; the oil
change is to be documented. This requirement may be waived if an oil analysis proves that the
oil is still usable.
16

ASD SFC
9_5714 06 E
3.5
Dangers
Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in Para. 15.
Tab. 33
3.5
Inspection
Inspection interval
Inspecting authority
Installation and equipment in

spection
Before initial start-up
Approved supervisory body
Internal inspection
every 5 years after installation or Competent person

the last inspection,
(e.g. KAESER service represen
tative)
Strength test
every 10 years after installation Competent person

or the last inspection,
(e.g. KAESER service represen
tative)
Inspection intervals according to Ordinance on Industrial Safety and

Health
Dangers
Basic Information
Information concerning the various forms of danger that can arise during machine operation are found
here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.5.1
Safely Dealing with Sources of Danger

Information concerning the various forms of danger that can arise during machine operation are found
here.
Electricity
Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec
trical engineering regulations .
Before every start-up, the user must make sure there is adequate protection against electric shock
from direct or indirect contact.
Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
Switch off any external power sources.
These could be connections to floating contacts or electrical machine heating, for example.
Use fuses corresponding to machine power.
Check regularly that all electrical connections are tight and in order.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or
death. The following information concernes work on components that could be under pressure.
9_5714 06 E

ASD SFC
17
3.5
Dangers
Close shut-off valves or otherwise isolate the machine from the air main to ensure that no com
pressed air can flow back into the machine.
Vent all pressurized components and chambers completely.
Do not carry out welding, heat treatment or mechanical modifications to pressurized components
(e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Compressed air quality
Never directly inhale compressed air.
Use appropriate systems for air treatment before using the compressed air from this machine as
breathing air and/or for the processing of foodstuffs.
Use foodstuff-compatible cooling oil whenever compressed air is to come into contact with food
stuffs.
Spring tension
Springs under tension or compression represent contained energy. Uncontrolled release of this en
ergy can cause serious injury or death.
Minimum pressure/check valves, pressure relief valves and inlet valves are powerfully spring-loaded.
Do not open or dismantle any valves.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result in
serious injury.
Do not open the enclosure while the machine is switched on.
present.
Wear close-fitting clothes and a hair net if necessary.
Make sure all covers and safety guards are in place and secured before starting.
Temperature
Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air lines, coolers,
oil separator tanks, motors and machine heaters.
Wear protective clothing.
If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
Noise
Operate the machine only with full soundproofing.
Wear hearing protection if necessary.
The pressure relief valve blowing off can be particularly loud.
Operating materials
Strictly forbid fire, open flame and smoking.
Follow safety regulations when dealing with lubricants and chemical substances.
18

ASD SFC
9_5714 06 E
3.5
Dangers
Avoid contact with skin and eyes.

Do not inhale oil mist or vapour.
Do not eat or drink while handling cooling and lubricating fluids.
Keep suitable fire extinguishing agents ready for use.
Use only KAESER approved operating materials.
Unsuitable spare parts
Use only spare parts approved by the manufacturer for use in this machine.
Unsuitable spare parts compromise the safety of the device.
Use only genuine KAESER pressure components.
Conversion or modification of the machine
Do not permit conversion or modification of the machine as this can compromise function and
safe working.
Extension or modification of the compressed air system
Extension or modification of the compressor station:
Check the blow-off capacity of pressure relief valves on air receivers and compressed air lines
before installing any new machines.
If the blow-off capacits is insufficient:
Install pressure relief valves with larger blow-off capacity.
3.5.2
Safe Machine Operation

Information on safe conduct when handling the machine is found here.
Transport
Use suitable lifting gear that conforms to local safety regulations.
Allow transport only by personnel trained in the safe movement of goods.
Attach lifting gear only to suitable lifting points.
Be aware of the centre of gravity to avoid tipping.
Make sure the danger zone is clear of personnel.
Installation
Install the machine in a suitable compressor room.
If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
Ensure adequate ventilation.
9_5714 06 E

ASD SFC
19
3.6
Safety Devices
Ensure that required ambient conditions are maintained with regard to:
ambient temperature and humidity,
clean inlet air with no damaging contaminants,
inlet air free of explosive or chemically unstable gases or vapours,
inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
Do not position the machine in warm exhaust air from other machines.
Ensure accessibility so that all work on the machine can be carried out without danger or hin
drance.
Decommissioning, storage, disposal
Drain out fluids and dispose of according to environmental regulations.
These include, for example, compressor oil and cooling water.
Give refrigerant only to authorised bodies for disposal.
Dispose of the machine in accordance with local environmental regulations.
3.5.3
Organisational Measures
Designate personnel and their responsibilities.
Give clear instructions on reporting faults and damage to the machine.
Give instructions on fire reporting and fire-fighting measures.
3.5.4
Danger Areas
The table gives information on the areas dangerous to personnel.
Only authorised personnel may enter these areas.
Activity
Danger area
Authorised personnel
Transport
Within a 3 m radius of the machine.
Installation personnel for transport prepa

ration.
No personnel during transport.
Installation
Beneath the lifted machine.
No personnel!
Within the machine.
Installation personnel
Within 1 m radius of the machine and its

supply cables.
Operation
Maintenance Within the machine.
Operating personnel
Maintenance personnel

Tab. 34
3.6
Danger Areas
Safety Devices
Various safety devices ensure safe working with the machine.
Do not change, bypass or disable safety devices.
Check safety devices for correct function regularly.
20

ASD SFC
9_5714 06 E
3.7
Safety Signs
Do not remove or obliterate labels and notices.

Ensure that labels and notices are clearly legible.
Further information
3.7
More information on safety devices is contained in chapter4, section 4.5.
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. 3
Location of safety signs

Item Sign
Meaning
Danger of fatal injury from electric shock!

Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no
voltage is present.
Hot surface!
Risk of burns caused by contact with hot components
Do not touch the surface.
Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
Risk of serious lacerations or even severing of extremities (fingers) from rotating com
ponents.
Operate the machine only with closed safety guards, access doors and panels.
voltage is present before opening any machine enclosure or guard.
Risk of injury caused by an automatic machine start!

voltage is present before opening any machine enclosure or guard.
Risk of fatal injury caused by dismantling valves (spring-loaded or under pressure)!

Do not open or dismantle the valve.
Call an authorized Service Technician if a fault occurs.
9_5714 06 E

ASD SFC
21
3.8
In Emergency
Item Sign
Meaning
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.
Incorrect oil levels can cause damage to the machine or excessive oil content in the
compressed air.
Check the oil level regularly and correct as necessary.
Tab. 35
3.8
3.8.1
Safety Signs
In Emergency
Fire fighting
Suitable extinguishing agents
Foam
Carbon dioxide
Sand or earth
Unsuitable or unsafe extinguishing agents
Strong jet of water
1. Keep calm.
2. Give the alarm.
3. Switch off the power supply disconnecting device, if possible.
4. Move to safety:
warn persons in danger
help incapacitated persons
close the doors
5. Try to extinguish the fire if you have the skill to do so.
3.8.2
Remove any cooling oil from your person.

Eye contact:
rinse thoroughly with lukewarm water and seek medical assistance.
Skin contact:
wash off immediately.
3.9
Warranty
This service manual contains no independent warranty commitment. Our general terms and condi
tions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended under
the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user to
determine its suitability for his specific application.
22

ASD SFC
9_5714 06 E
3.10
Environmental Protection
In addition, we accept no warranty obligation for:
the use of unsuitable parts or operating materials,
unauthorised modifications,
incorrect maintenance,
incorrect repair.
Correct maintenance and repair includes the use of original spare parts and operating materials.
Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.10
Environmental Protection
Store and dispose of operating materials and replaced parts in accordance with local environ
mental protection regulations.
Observe relevant national regulations.
This applies particularly to parts contaminated with cooling oil.
Do not allow cooling oil to escape to the environment or into the sewage system.
9_5714 06 E

ASD SFC
23
Design and Function
4.1
Outline of the Machine
4 Design and Function

4.1
Outline of the Machine
Fig. 4
Enclosure
1
2
3
Control cabinet door

Latch
Panel (removable)
The enclosure, when closed, serves various functions:
sound insulation
protection against contact with components
cooling air flow control
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.
4.2
Functional Description
The function description uses an air-cooled machine as an example.
24

ASD SFC
9_5714 06 E
Fig. 5
Design and Function
4.2
Functional Description
Machine layout
1
2
3
4
5
Inlet valve
Minimum pressure/check valve
Drive motor
Oil filter
Airend
6
7
8
9
10
Control cabinet
oil separator tank
Air filter
Oil/air cooler
Add-on cabinet for frequency converter / re
frigeration dryer
Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the rotors
themselves and between them and the airend casing. This direct cooling in the compression chamber
ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure within
the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve main
tains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pressure/
check valve 2 into the air cooler 9 . The minimum pressure/check valve ensures that there is always
a minimum internal air pressure sufficient to maintain cooling oil circulation in the machine.
The air cooler brings down the compressed air temperature of only 5 to 10 K above ambient. Most of
the moisture carried in the air is removed during this cooling process.
4.2.1
Frequency Converter
The machine is equipped with a frequency converter that regulates motor speed in proportion to the
air demand.
Observe the manufacturer's documentation supplied with the machine in addition to the
instructions in this service manual.
9_5714 06 E

ASD SFC
25
4.2.2
Design and Function
4.3
Options
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
Options
The options available for your machine are described below.
4.3.1
Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 6
4.3.2
Machine mountings
Optional Filter Monitoring Set

Sensors monitor the operational state of the filter. Indication is given as soon as maintenance is
required.
The following filters are monitored:
4.3.3
Air filter
Oil filter
Oil separator cartridge
Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
Fig. 7
Cooling air filter mat (option K3)

1
26
Cooling air filter mat

ASD SFC
9_5714 06 E
4.3.4
Option W1
Design and Function
4.4
Operating Modes and Control Modes
Option W1/W2/W3
Heat Recovery
Prepared for external heat recovery
Connections are provided and bridged.
An external heat recovery system can be retrofitted at any time.
Option W2/W3
Internal heat recovery

A plate-type heat exchanger is installed for internal heat recovery.
Fig. 8
Internal heat recovery (option W2/W3)

1
4.4
4.4.1
Plate-type heat exchanger

Operating modes
The machine operates in the following modes:
4.4.2
LOAD:
The inlet valve is open. The block delivers compressed air to the air system.
The drive motor runs under full load.
IDLE:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the
air system. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.
The drive motor runs unloaded, with low power consumption.
STANDSTILL:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the
air system. The oil separator tank is vented.
The drive motor is stopped.
Control modes
Using the selected control mode, the controller switches the drive motor according to definite rules
(the control mode) between the various operating modes in order to compensate for air being drawn
off by consumers and maintain the machine's working pressure between the preset cut-in and cutout pressures.
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27
Design and Function
4.4
SIGMA CONTROL can work in the following control modes:
DUAL
QUADRO
VARIO
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain pressure between the preset minimum and maximum values. When maximum pressure is
reached, the machine switches to IDLE. When the preset idle period has elapsed, the machine
switches to STANDSTILL.
The shorter the idle period setting, the sooner (and more frequently) the motor is stopped.
QUADRO
In the QUADRO mode, the controller operates as in the DUAL mode during periods of high air demand
by switching between LOAD and IDLE, but during periods of low air demand it switches directly to
STANDSTILL.
This mode of control requires two preset time periods: the running period and the idle/standstill pe
riod.
The shorter these periods, the sooner (and more frequently) the motor stops.
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idle peri
od is automatically lengthened or shortened to compensate for higher or lower drive motor starting
frequencies.
4.4.3
Frequency-Controlled Drive (SFC)

When the machine runs in LOAD, the frequency converter compensates for deviations between
SETPOINT pressure and ACTUAL pressure by changing the speed of the drive motor and, thereby,
the airend.
The speed of the airend determines the delivery of the machine and thereby the system pressure.
These changes in speed match the air delivery to the air consumption and keep system pressure as
constant and as close as possible to the SETPOINT pressure.
This functions within the control range of the machine between minimum and maximum delivery
(Vmin und Vmax).
If the air demand falls below the minimum delivery rate of the compressor (Vmin) the system pressure
will continue to rise.
The machine switches to IDLE at the latest when system pressure rises to 0.4 bar above SETPOINT
pressure (p1).
If SETPOINT pressure corresponds to the maximum working pressure, the machine switches
to IDLE at the latest 0.4 bar above maximum working pressure. This increase in pressure is to
be taken into account in the design of the overall compressed air supply system.
28

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4.5
Design and Function
4.5
Safety Devices
Safety Devices
The following safety devices are provided and may not be modified in any way:
EMERGENCY STOP button:

The EMERGENCY STOP button shuts down the machine immediately. The motor remains stop
ped. The pressure system is vented.
Pressure relief valve:

The pressure relief valve protects the machine from excessive pressure. It is preset at the factory.
Door interlock switches:

The machine will stop automatically if a door or panel fitted with these safety interlocks is opened
or removed.
Enclosures and guards for moving parts and electrical connections:

These protect against accidental contact.
4.6
SIGMA CONTROL Keys and Indicators
Fig. 9
Keys
Item Description
Function
Switches on the machine.
ON
The programmed operating mode is active.

2
OFF
Switches the machine off.
Clock
Switches clock control on and off.
Remote control
Switches remote control on and off.
LOAD/IDLE
Toggles the compressor between LOAD and IDLE operating

modes.
DOWN
Scrolls down the menu options.

Reduces a parameter value.
UP
Scrolls up the menu options.

Increases a parameter value.
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29
Design and Function
4.6
Item Description
Function
Returns to the next higher menu option level.
escape
Exits the edit mode without saving.

Returns to the main menu when held down at least 10 seconds.
9
enter
Only affects the value in the third line of the display.

Enters the selected menu option.
Exits the edit mode and saves.
10
Events and information Displays the event memory.

Selection is possible from every menu.
Return with esc key.
11
Reset
Signifies recognition of alarms and warning messages.

Resets the event memory (when permitted).
Tab. 36
Fig. 10
Keys
Indicators
Item Description
Function
12
Display field
Alphanumeric display with 4 lines.
13
Alarm
Flashes red when an alarm occurs.

Lights continuously when acknowledged.
14
Communication
Lights red if communication via the Profibus interface is interrupted.
15
Warning
Flashes yellow for:
maintenance work due,
warning messages
Lights continuously when acknowledged.

16
Controller power
Lights green when the power supply to the controller is switched on.
17
LOAD
Lights green when the compressor is running under LOAD.
18
IDLE
Lights green when the compressor is running in IDLE.

Flashes when the LOAD/IDLE toggle key is pressed.
19
30
Machine ON
Lights green when the machine switched on.

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Design and Function
4.6
Item Description
Tab. 37
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Function
20
Clock
The LED lights when the machine is in clock control.
21
Remote control
The LED lights when the machine is in remote control.
Indicators

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31
5.1
Safety
5 Installation and Operating Conditions

5.1
Safety
Strictly forbid fire, open flame and smoking.
If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
The machine is not explosion-proof:
Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
Ensure that required ambient conditions are maintained with regard to:
ambient temperature and humidity,
clean inlet air with no damaging contaminants,
inlet air free of explosive or chemically unstable gases or vapours,
inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
Keep suitable fire extinguishing agents ready for use.
5.2
5.2.1
Installation Conditions
Place of installation and distances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma
chine parts.
Please consult KAESER if they cannot be kept to.
Precondition
32
The floor must be level, firm and capable of bearing the weight of the machine.

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Fig. 11
5.2
Installation Conditions
Recommended installation and dimensions [mm]

A
B
Z
Exhaust fan
Exhaust air duct
Cooling air inlet aperture
CAUTION
Ambient temperature too low!
Frozen condensate and highly viscous cooling oil can cause damage when starting the machine.
Make sure that the temperature of the machine is at least +3 C before starting.
Heat the machine room adequately or install an auxiliary heater.
1. If installed outdoors, protect the machine against frost, direct sunlight, dust and rain.
2. Ensure accessibility so that all work on the machine can be carried out without danger or hin
drance.
5.2.2

If the ventilation is insufficient, a dangerous vacuum can build up in the machine room.
Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually
open.
Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the machine room.
5.2.3
Exhaust duct design

The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by
the duct design. Any additional air resistance will reduce airflow and deteriorate machine cooling.
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33
5.3
Operating the Machine in an Air System.
Consult the KAESER service representative before deciding on:
the design of the exhaust air ducting
the intersection between the machine and the exhaust air duct
the length of the ducting
the number of duct bends
the design of flaps or shutters

Use only motorised ventilation flaps and louvers on variable frequency drive (SFC) machines.
Flaps or louvers that open through the pressure of the airflow against the force of gravity do not
open sufficiently at low cooling fan speeds.
Further information
5.3
Further information on installation of exhaust air ducts can be found in chapter 13.2.
Operating the Machine in an Air System.

If the machine is supplying an air system, the system operating pressure may not exceed 16 bar.
When charging a fully vented air system there is generally a very high rate of airflow through the air
treatment devices. These cannot function correctly under such conditions. Air quality suffers.
To ensure the desired air quality when charging a vented air network, we recommend the installation
of an air main charging system.
Consult KAESER for advice on this subject.
34

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Installation
6.1
Safety
6 Installation
6.1
Safety
Follow the instructions below for safe installation.
Warning instructions are always given before a potentially dangerous action.
Basic safety instructions
1. Follow the instructions in chapter 3 'Safety and Responsibility'.
2. Installation work may only be carried out by authorized personnel.
3. Before switching on, make sure that:
no one is working on the machine,
all access doors and panels are closed and secure.
Working on live components.

1. Work on electrical equipment may only be carried out by authorized electricians.
2. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
3. Check that there is no voltage on floating relay contacts.
Working on pressure systems
1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all hose couplings in the compressed air system with a hand-held pressure gauge to en
sure that they all read 0 bar.
4. Do not open or dismantle any valves.
Working on the drive system
1. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
2. Do not open the cabinet while the machine is switched on.
Further information
Details of authorized personnel are found in chapter 3.4.2.

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

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

The compressed air system is vented completely.

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35
Fig. 12
Installation
6.4
Connecting the Power Supply
Compressed air connection

1
2
Axial compensator or hose

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

The machine is disconnected from all power supply phases.
The disconnecting device is locked in the off position.
A check has been made that no voltage is present.
1. Have the power supply connected only by authorized installation personnel or an authorized
electrician.
2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example or
DIN VDE 0100) and in national accident prevention regulations (BGV A3 in Germany). In addition,
observe the regulations of the local electricity supplier.
3. Check the permitted disconnect time for the overload protection cut-out if a fault arises.
4. Select supply cable conductor cross-sections and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is used
it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the supply
voltage.
If not, change the tappings to suit the power supply voltage.
DANGER
Danger of fatal injury from electric shock!
present.
When working on the frequency converter or intermediate circuit condensers,
wait at least 5 minutes for dangerous voltages to subside.
7. Connect the machine to the power supply.
Further information
36
The electrical diagram in chapter 13.3 contains further details of the power supply connection.

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6.5
Material
Precondition
Installation
6.5
Connecting the External Pressure Transducer
Connecting the External Pressure Transducer

Retrofit kit: External pressure transducer SC USS
Use suitable screened, copper-core cable (e.g.: LIYCY 2 x 0.75 mm2 for ambient temperatures up to
30 C and laying method C).
The power supply disconnecting device is switched off.
Cable length between the machine and the pressure transducer: <50 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 isolating transformer in the control cabinet.
2. Connect the power supply for the isolating amplifier.
3. Make the connection between the output of the isolating amplifier and the analog input of the
frequency controller.
4. Install the pressure transducer at the selected location in the compressed air network.
5. Using a suitable cable, connect the pressure transducer to the isolating amplifier 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. When commissioning the machine, activate <FC USS> in the menu option <system actual pres
sure> in the compressor's SIGMA CONTROL.
Further information
6.6
6.6.1
The electrical diagram in chapter 13.3 contains further details of the pressure transducer connection.
Options
Option H1
nchoring the machine
Use appropriate fixing bolts to anchor the machine.
Further information
6.6.2
Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.
Option W1/W2/W3
Connecting the Heat Recovery System
Take the electrochemical series into consideration and choose suitable materials for con
nections.
Keep the effect of pressure surge on the heat exchanger as low as possible.
Install an expansion tank to act as a damper if pressure surges cannot be avoided.
Install appropriate regulating devices if the heat transfer medium is to be kept constant.
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37
Installation
6.6
Options
WARNING
Cooling oil in the heat transfer medium.
Oil may contaminate the medium if a leak occurs.
Do not use the transfer medium as drinking water.
6.6.2.1
Option W1
Connecting the external heat recovery system
An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within
the compressor. Damage to the machine will follow.
Consult KAESER on a suitable heat exchanger and expert installation.
Carry out installation and connection of the heat exchanger in accordance with specifications
from KAESER and the exchanger manufacturer.
6.6.2.2
Option W2/W3
Connecting the internal heat recovery system
Fig. 13
Connecting the heat recovery system

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

17 Pressure relief 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.

Blowoff pressure and capacity are related to the user's installation design. The technical
specification of the heat exchanger must be taken into consideration.
2. Connect the supply lines and fittings

3. Open the shut-off valve 10 at the inlet A .
4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the heat
transfer medium.
5. Bleed the lines.
Further information
38
The dimensional drawing in chapter 13.2 gives the flow direction, size and position of the connection
ports.

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Initial Start-up
7.1
Safety
7 Initial Start-up
7.1
Safety
Instructions for Safe Initial Start-up of the Machine.
Warning instructions are always given before a potentially dangerous action.
2. Have installation work carried out by authorized installation personnel only.
no one is working on the machine,
Working on live components

1. Have work on electrical equipment carried out by authorized electricians only.
2. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt
age is present.
1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
age is present.
Further information

7.2
Instructions to be Observed before Every Commissioning or Recommissioning

Incorrect or improper commissioning can cause injury to persons and damage to the machine.
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39
Initial Start-up
7.3
Checking Installation and Operating Conditions
Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage
Storage period longer than: Action
12 months
Change the oil filter

Change the oil separator cartridge
Change the cooling oil
Have the motor bearings checked by an authorized KAESER Serv
ice Technician.
Have the frequency converter smoothing condensers formed by an
authorised KAESER Service Technician.
36 months
Tab. 38
7.3
Have the overall technical condition checked by an authorized

KAESER Service Technician.
Re-commissioning after storage
Checking Installation and Operating Conditions

Check and confirm all the items in the checklist before initially starting the machine.
To be checked
See chapter Confirmed
Are the operators fully conversant with safety regulations?
Have all the installation conditions been fulfilled?
Is a user's lockable power supply disconnecting device installed?
6.4
Does the power supply conform to the specifications on the nameplate? 2.1
Are the power supply cable conductor cross-sections and fuse ratings 2.14
adequate?
Have all electrical connections been checked for tightness?
(The check must be repeated after 50 operating hours).

Is a shut-off valve fitted to compressed air outlet?
6.3
Has the connection to the air system been made with a hose or axial 6.3
compensator?
Tab. 39
40
Is there sufficient cooling oil in the separator tank?

(cooling oil level indicator outside the red zone)
10.12
Is there sufficient cooling oil in the airend?
7.6
Is the machine firmly anchored to the floor?

(option H1)
6.6.1
Are all access doors closed and latched and all removable panels in
place and secured?
Installation conditions checklist

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7.4
Initial Start-up
7.4
Commissioning the Frequency Converter
Commissioning the Frequency Converter

The frequency converter parameters are preset. Adjustment of parameters to suit operating condi
tions on site is done by trained and authorised personnel.
Changes to the factory settings may influence the whole machine. The machine may break down or
be damaged.
Allow only trained and authorized personnel to make parameter changes.
7.5
Setting the Motor Overload Protection Switch

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

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to pour a quantity of cooling oil into the airend.
A label showing the type of oil used is found near the oil separator tank filling port.
Use the same type of oil.
Material
Precondition
Fig. 14
1 lCooling oil
Inlet valve filling port

1
2
Screw plug
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.
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41
Fig. 15
Initial Start-up
7.7
Checking Direction of Rotation
Coupling
1
2
Airend
Coupling
3
4
Safety screen
Arrow showing direction of rotation
1. Remove the safety screen 3 .

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

The machine is designed for a clockwise phase sequence.
In frequency-controlled compressors, the direction of rotation of the fan motor may be incorrect even
if the compressor motor is correct.
Ideally, the direction of phase rotation should be measured with a phase sequence meter.
Alternatively, start the machine very briefly and observe the direction of rotation of the motor cooling
fan.
1. Check the direction of phase rotation with a phase sequence meter.
2. If the drive motor turns in the wrong direction, swap motor supply phases L1 and L2.
3. If the fan motor is incorrect, change the machine supply phases L1 and L2.
You have no phase sequence meter?
Switch the machine on and off again the moment the drive motor begins to turn.
Compare the direction of rotation of the motor with the arrows on the motor and the airend
casing.
Compare the direction of rotation of the fan with the arrow on the motor casing.
If the direction is wrong, swap phase connections as described.
7.8
Precondition
Starting the Machine for the First Time

No personnel are working on the machine,
all access doors are closed,
all removable panels in place and secured.
1. Open the shut-off valve to the air system.
2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Power ON LED lights continuously.
3. If required:
Change the display language as described in chapter 7.10.
42

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Initial Start-up
7.9
Setting the Setpoint Pressure
4. Press the LOAD/IDLE key.

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

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

The controller can display text messages in several languages. The display language can be changed
first during initial start-up.
A label explains how this is done with the help of icons.
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43
Fig. 16
Initial Start-up
7.10
Changing the display language
Label: Changing the display language

1
2
3
4
If required:
Unlatch the EMERGENCY STOP button.
If required:
Acknowledge alarm message.
Depress the escape key for 5 seconds to
change to the main menu.
Press the UP key 8 times.
5
6
7
8
Press Enter to enter language selection.

Press the UP or DOWN keys as often as
necessary to reach the required language.
Press enter to select the language.
Depress the escape key for 5 seconds to
change to the main menu.
Change the display language on SIGMA CONTROL as required.
44

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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. 17
Switching on and off

1
2
8.1.1
Precondition
Machine ON LED (green)

ON key
3
8
OFF key
Controller ON LED (green)
Switching on
No personnel are working on the machine,
1. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Power ON LED lights continuously.
2. Press the ON key.
The green Machine ON LED lights continuously.
If a power failure occurs, the machine is not prevented from automatic re-starting.
It can start automatically again as soon as power is restored.
Result
8.1.2
The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cutout pressure).
Shutdown
1. Press the LOAD/IDLE key.
The machine switches to IDLE and the IDLE LED flashes.
2. After allowing the machine to IDLE for 20 seconds:
press the OFF key.
The Machine ONLED extinguishes.
The machine is ready for operation. The machine can now be started again.
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45
Operation
8.2
Switching Off in an Emergency and Switching On again
3. Switch off and lock out the power supply disconnecting device.
The machine is switched off and isolated from the mains supply. The Controller ONLED extin
guishes.
8.2
Switching Off in an Emergency and Switching On again

The EMERGENCY STOP pushbutton is located below the control panel.
Fig. 18
Switching off in an emergency

9
EMERGENCY STOP pushbutton
Shutdown
Press the EMERGENCY STOP pushbutton.
The pushbutton remains latched in.
The compressor's pressure system is vented and the machine is prevented from automatically
re-starting.
Switching on
Precondition
The fault has been rectified

1. Turn the EMERGENCY STOP pushbutton in the direction of the arrow to unlatch it.
2. Press the reset key to reset any alarm messages.
The machine can now be started again.
8.3
Acknowledging Alarm and Warning Messages

Messages are displayed on the "new value" principle:
Message received: LED flashes
Message acknowledged: LED lights
Message gone: LED extinguished
or
46
Message received: LED flashes
Message gone: LED flashes
Message reset: LED extinguished

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Fig. 19
Operation
8.4
Remote On and Off Switching
Acknowledging/resetting messages
10 warning (yellow) LED
11 alarm (red) LED
12 acknowledge/reset key
Alarm message
Precondition
Fault has been rectified

Reset the message with the acknowledge/reset key.
alarm LED extinguishes.

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

Maintenance has been carried out
Reset the message with the acknowledge/reset key.
warning LED extinguishes.
8.4
Precondition
9_5714 06 E
Remote On and Off Switching

A remote control device is linked.

ASD SFC
47
Fig. 20
Operation
8.5
Switching On and Off with the Clock
Switching on and off in remote

1
2
remote control key

remote control LED
1. Attach an easily seen notice that warns of remote machine operation.

DANGER!
This machine is remotely controlled and can start automatically at any time.
Tab. 40
Machine identification
2. Label the starting device in the remote control centre as follows:
DANGER!
Before starting, make sure that no one is working on the machine and that it can be safely started.
Tab. 41
Remote control identification

3. Press the remote key.
The remote LED lights. The machine can be remotely controlled.
8.5
Precondition
48

The clock is programmed.

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Fig. 21
Operation
8.5
Switching on and off with the clock

1
2
clock key
clock key
1. Attach an easily seen notice warning of time-controlled operation:

DANGER!
This machine is time-controlled and can start automatically at any time.
Tab. 42
Machine identification
2. Press the clock key.
The clock LED lights. The machine is switched on and off by the clock.
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49
9.1
Basic Information
9 Fault Recognition and Rectification

9.1
Basic Information
The following tables are intended to assist in locating faults.
There are three types of fault:
Alarm: red LED flashes - see chapter 9.2.
Warning: yellow LED flashes - see chapter 9.3.
Other faults: no indication - see chapter 9.4.
The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault removal measures other than those given in this manual.
2. In all other cases:
have the fault rectified by an authorised KAESER service representative.
9.2
Alarm Messages (machine shutdown)

Message
Possible cause
Remedy
blowoff prot.
The activating pressure of the pres

sure relief valve on the oil separator
tank has been exceeded.
Change the oil separator cartridge.
sh.cct.AI1
sh.cct.AI2
The connection between the sensor

and the analog input is shorted.
Check line and connections.
AI3/AI4 error
Line-break between the analog input Check line and connections.

and the sensor.
Open the shut-off valve in the vent

ing line.
Short circuit to earth.

sh.cct AI5
sh.cct AI6
The connection between the sensor

and the analog input is shorted.
AI7/AI8 error
Line-break between the analog input Check line and connections.

and the sensor.
Short circuit to earth.
Model
Machine model uncertain
Call KAESER service representa

tive.
bus alarm
The bus link from the Profibus DP in Check line and settings.
terface is defective.
PD
Package discharge (PD) temperature Call KAESER service representa

too low.
tive.
PD -
Package discharge (PD) temperature Check the cooling oil level.

too high.
Clean the cooler.
Check the fan motor.
50
DO0.6/DO0.7 I
Short circuit in the line between the

digital output and the consumer.
DO1.6/DO1.7 I
Short circuit in the line between the

digital output and the consumer.

ASD SFC
9_5714 06 E
9.2
Message
Possible cause
Remedy
Airend rotation
The drive motor is turning in the wrong Swap phase lines L1 and L2.
direction.
error: RS485USS
SFC machine with USS protocol:

RS485 transmission
SIGMA CONTROL frequency convert
er faulty.
Check the connection between the

frequency converter and
SIGMA CONTROL.
Check configuration of the RS485.
tive.
ext. message 0
ext. message 1
ext. message 2
ext. message 3
ext. message 4
ext. message 5
Customer specific:
no details possible.
back pressure
Back pressure in the oil separator tank Check venting line.

caused by defective venting.
HT cell
Fault in the high tension cell.
V-belts ruptured
The drive belts have parted during ma Replace drive belts.

chine operation.
no press.buildup
The machine produces no com

pressed air.
Check the machine for leaks.
condensate drain.
The condensate drain is defective.
Check the condensate drain.
coolingwater low
Cooling water pressure is too low.
Check cooling water supply.

tive.
Check coupling / V-belts

The working pressure does not rise Call KAESER service representa
above 3.5 bar within a default period. tive.
Cooling water throttling valve:

check setting.
RD p
The pressure switch for the refrigerant Keep ambient conditions within
compressor has activated.
specified limits.
Clean the refrigerant condenser.
Clean the cooler.
RD T
Temperature in the refrigeration dryer Ensure adequate ventilation.

too high.
Clean the cooler.
Install an extractor fan.
fan M2 I
Overload shutdown of the first fan mo Investigate cause of shutdown.

tor.
Reset overload trip.
tive.
fan M3 I
Overload shutdown of the second fan Investigate cause of shutdown.

motor.
tive.
9_5714 06 E

ASD SFC
51
9.2
Message
Possible cause
Remedy
fan M4 I
Overload shutdown of the third fan mo Investigate cause of shutdown.

tor.
tive.
fan M7 I
Overload shutdown of the control cab Investigate cause of shutdown.

inet fan motor.
tive.
motor I
Overload shutdown of the compressor Investigate cause of shutdown.

drive motor.
tive.
motor T
Drive motor overheated.
Clean the motor.

Keep ambient conditions within
specified limits.
motor bearings
Drive motor bearings overheated.
Grease the motor bearings.

tive.
mains cont. on?
Mains contactor not pulling in.
Check mains contactor and wiring.
mains cont. off?
Mains contactor not dropping out.
Check mains contactor and wiring.
mains voltage
2nd power failure.
Check power supply voltage.

Check the door interlock switch.
mains monitor
Fault in mains power supply.
Have the mains power supply

checked.
Emergency stop
EMERGENCY STOP pushbutton

pressed.
Unlatch the pushbutton.
OST dp
Oil separator cartridge clogged.
OST T
Maximum air temperature at the oil

separator tank outlet is exceeded.
Check the line to the trip relay.
oil p
The machine cannot switch to LOAD Check the oil circulation.

until the minimum oil pressure is
Check the pressure switch, line and
reached.
connection.
p-switch
Customer specific:
pRV
The activating pressure of the pres

sure relief valve on the oil separator
tank has been exceeded.
Change the pressure relief valve.
FC
Frequency converter faulty.

tive.
SIGMA CONTROL T The maximum permissible

SIGMA CONTROL housing tempera specified limits.
ture has been exceeded.
Control cabinet:
check filter mats and fan.
Softstart
52
Fault in the soft start equipment.

ASD SFC

tive.
9_5714 06 E
9.3
Warning Messages (yellow LED lights)
Message
Possible cause
Remedy
start T
Airend discharge temperature (ADT) Keep ambient conditions within

too low.
specified limits.
Ambient temperature: < +2 C
T switch
Customer specific:
ADT
The airend discharge temperature

(ADT) did not reach the minimum val tive.
ue required within the specified time.
ADT
Maximum permissible airend dis

charge temperature (ADT) exceeded. specified limits.
Clean the cooler.
Check the cooling oil level.
Tab. 43
9.3
ADT dT/dt
Airend discharge temperature (ADT) Check the cooling oil level.

rising too quickly.
tive.
access doors
Door open / interlocked panel re

Fit and secure all panels and close
moved while the machine is running. access doors.
Alarm messages and measures

Message
Possible cause
Remedy
blowoff prot.
The activating pressure of the pressure Change the oil separator cartridge.
relief valve will soon be reached.
Open the shut-off valve in the venting
line.
bus alarm
The bus link from the Profibus DP in

terface is interrupted.
Check bus highway and plug.
PD temperature Package discharge (PD) temperature Call KAESER service representative.

too low.
PD temperature Package discharge (PD) temperature Clean the cooler.
too high.
elect. equip. h
The maintenance interval for checking Carry out the check and reset the main
electrical equipment and wiring has ex tenance interval counter.
pired.
error: FEPROM
Internal controller memory error.
Call KAESER service representative.
error: RS 485PP
Wrong configuration or transmission

error.
Check the link/interface connections

between the two controllers.
Check maximum cable length and
screening.
1 master and 1 slave configured.
error SMS
9_5714 06 E
SMS can not be sent.

ASD SFC
53
9.3
Message
Possible cause
Remedy
ext. message 0
ext. message 1
ext. message 2
ext. message 3
ext. message 4
ext. message 5
Customer specific:
FC AI1 fault
SFC machine:
Air system pressure sensor to AI1 de
fective.
FC MM Service
SFC machine:
Deactivate the service mode as soon
Service mode for frequency converter. as the frequency converter settings are
completed.
FC mains
SFC machine:
Power supply failure to the frequency
converter.
Check power supply.
annual maint
Last maintenance was one year ago.
Carry out the necessary maintenance

and reset the corresponding mainte
nance interval counter.
no press.buildup
The compressor cannot build-up to

working pressure.
Check for air leaks.
condensate drain
The condensate drain is defective.
Check the condensate drain and drain

line.
RD T
Refrigeration dryer:
Compressed air temperature too low.
RD p
Pressure in the refrigerant circuit too
low.
Inlet pressure switched tripped.
RD p
Pressure in the refrigerant circuit too
high.
Pressure relief switch tripped.
Keep ambient conditions within speci

fied limits.
Check the value for internal pressure

given in the <analog data> menu
against the reading on the oil separator
tank pressure gauge.

Check the fan motor.
bearing.maint. h The maintenance interval for greasing Grease the motor bearings.
the bearings has expired.
ext.load signal?
Ambiguous external load signal:

Check settings of the external control
Increased cut-out pressure exceeded. ler. Take into account pressure drops
across filters and dryers.
The external load control has not
switched to idle (off load).
54
air filter dp
Air filter clogged.
Carry out air filter maintenance.
air filter dp
Air filter clogged.
Carry out air filter maintenance.
air filter h
Maintenance interval for air filter check Check the air filter.
has elapsed.

ASD SFC
9_5714 06 E
9.3
Message
Possible cause
Remedy
modem problem
SIGMA CONTROL does not recognise Check the link between

the modem.
SIGMA CONTROL and the modem.
motor T
Drive motor overheating.
Clean the motor.

fied limits.
motor starts /h
The permissible number of motor starts Extend the idle period.

was exceeded during the last 60 mi Increase the capacity of air receiver.
nutes.
Increase the cross-section of piping be
tween compressor and air receiver.
motor starts /d
The permissible number of motor starts Extend the idle period.

was exceeded during the last 24 hours. Increase the capacity of air receiver.
Increase the cross-section of piping be
tween compressor and air receiver.
bearingchange h The maintenance interval for checking Have the motor bearings checked by an
the bearings has expired.
authorized KAESER service represen
tative.
system press.
Air system pressure has fallen below

the "low" value.
Air consumption too high.
Check air demand.

Check transducer connections and wir
ing.
Check the 'sys.press. low' warning set
ting.
system press.
Air system pressure is above the

"sys.press. high" value.
Check for air leaks.

Check the 'sys.press. high' warning set
ting.
Check whether the machine switches
to LOAD.
mains voltage
1. Power failure:
Check power supply.
The machine was re-started automati Check the door interlock switch.
cally.
OS dp
The pressure drop across the oil sepa Change the oil separator cartridge.
rator cartridge has risen.
Oil separator cartridge clogged.
OS h
The interval for the next oil separator

cartridge check has expired.
oil filter dp
The pressure drop across the oil filter Change the oil filter.
has risen.
Oil filter clogged.
oil filter h
The interval for the next oil filter check Change the oil filter.
has expired.
Oil level
Cooling oil level too low.
Top up the cooling oil.
oil T
Cooling oil temperature too low.
Check temperature switch, line and

connection.
Check the oil circulation.
Increase room temperature.
9_5714 06 E

ASD SFC
55
9.3
Message
Possible cause
Remedy
oil change h
The interval for the oil change has ex Change the cooling oil.
pired.
p-switch
Customer specific:
buffer battery
Data retention battery is almost dis

charged.
Change the battery.
error: RAM
Internal RAM defective.
oil content
The oil content limit for pure air will soon Check the scavenge tube in the oil sep
be reached.
arator cartridge.
Check the dirt trap strainer in the scav
enge line.
Check air treatment upstream of the
measuring point.
V-belt tension
Belt tension is too low.
Re-tension drive belts.
blt.coup.insp.h
The maintenance interval for V-belt ten Carry out a visual check.
sion / coupling inspection has expired. Re-tension drive belts.
start T
The airend temperature is too low (< Keep ambient conditions within speci
10 C) for the machine to be operated. fied limits.
start T
The airend temperature is too low (<

+2 C).
set output
The 'set outputs' test function is activa Stop the 'set output' mode.
ted.
T switch
Customer specific:
TRAP interrupt
System message:
TRAP interrupt
ADT
Airend discharge temperature has al

most reached maximum.
Clean the cooler.

fied limits.

Replace the oil filter.
Keep surrounding temperature within
recommended limits.
access doors
Tab. 44
56
Doors opened with the machine stop Close access doors.

ped.
Warning messages

ASD SFC
9_5714 06 E
9.4
9.4
Other Faults
Other Faults
Fault
Possible cause
Remedy
Machine runs but produces no

compressed air.
Inlet valve not opening or only

opening partially.
Call KAESER service represen

tative.
Venting valve not closing.

tative.
Leaks in the pressure system.
Check pipework and connec

tions for leaks and tighten any
loose fittings.
Air consumption is greater than Check the air system for leaks.
the capacity of the compressor. Shut down the consumer(s).
Hose coupling or maintenance Remove coupling or mainte
hose still plugged into the quick- nance hose.
release coupling on the oil sep
arator tank.
Cooling oil runs out of the air fil Oil level in the oil separator tank Drain off oil until the correct level
ter.
too high.
is reached.
Inlet valve defective.

tative.
Compressor switches between Air receiver too small.

Increase size of air receiver.
LOAD and IDLE more than twice Airflow into the compressed air Increase air pipe diameters.
per minute.
network restricted.
Check filter elements.
The differential between cut-in
and cut-out pressure too is
small.
Check switching differential.
Cooling oil leaking into the floor Hose coupling or maintenance Remove coupling or mainte
pan.
hose still plugged into the quick- nance hose.
release coupling on the oil sep
arator tank.
Oil cooler leaking.

tative.
Leaking joints.
Tighten joints.
Replace seals.
Cooling oil consumption too

high.
Unsuitable oil is being used.
Use SIGMA FLUID cooling oil.
Oil separator cartridge split.
Change the oil separator car

tridge.
Oil level in the oil separator tank Drain off oil until the correct level
too high.
is reached.
Oil return line clogged.
Tab. 45
9_5714 06 E
Check dirt trap in the return line.
Other faults and actions

ASD SFC
57
10
Maintenance
10.1
Safety
10 Maintenance
10.1
Safety
Follow the instructions below to ensure safe machine maintenance.
Warning instructions are located before a potentially dangerous task.
2. Maintenance work may only be carried out by authorized personnel.
no personnel are working on the machine,
Working on live components

1. Work on electrical equipment may only be carried out by authorized electricians.
age is present.
4. Before starting work on the frequency converter or intermediate circuit condensers, wait at least
5 minutes.
Dangerous voltages persist in the frequency converter and intermediate circuit condensers for
some time after power is switched off.
Power and control terminals may still be live when the motor is stopped.
Live components are exposed when the frequency converter cabinet is opened.
In addition to this manual, pay attention to the operating instructions delivered with the
frequency converter.
1. Close shut-off valves or otherwise isolate the machine from the compressed air network to ensure
age is present.
Further information

58

ASD SFC
9_5714 06 E
10
Maintenance
10.2
Maintenance Schedule
10.2
10.2.1
Logging maintenance work

The maintenance intervals given are those recommended for average operating conditions.
Maintenance tasks should be carried out more frequently where operating conditions are
unfavourable (e.g. dusty atmosphere) or when the equipment is in constant use.
Adjust the maintenance intervals with regard to local installation and operating conditions.
Keep a log of all maintenance and repair work.
This enables the frequency of individual maintenance tasks and deviations from our recommen
dations to be determined.
Further information
10.2.2
A prepared list is provided in chapter 10.18.
Resetting maintenance interval counters

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

service message acknowledged and
password level 4 activated.
1. Select the appropriate entry in the "Maintenance" menu.
2. Select 'reset' and 'y' and confirm with the enter key.
Further information
10.2.3
Detailed information can be found in the SIGMA CONTROL operating instructions.
Regular Maintenance Tasks

The table below lists maintenance tasks required.
9_5714 06 E

ASD SFC
59
10
Maintenance
10.2
Take note of the controller's service messages and carry out tasks punctually taking ambient and
operating conditions into account.
Interval
Maintenance task
See chapter
Weekly
Check the cooling oil level
10.12
Control cabinet:
check the filter mat
10.4
Check the air filter
10.7
Clean the cooler
10.5
Option K3:
clean the cooling air filter mat
10.3
Check the coupling
10.9
Change the air filter element
10.7
Option K3:
change the cooling air filter mat
10.3
Control cabinet:
change the filter mat
10.4
Change the oil filter
10.16
Change the oil separator cartridge
10.17
Variable (see table 47)
Change the cooling oil
10.15
Annually
Check that all electrical connections are tight
Check the pressure relief valve
10.10
Check the overheating safety shutdown function
10.11
Check the cooler for leaks
10.5
Up to 1,000 h
SIGMA CONTROL dis

play
Up to 3,000 h
SIGMA CONTROL dis

play
Up to 6,000 h
At least annually
SIGMA CONTROL dis
play
Up to 6,000 h
At the latest every 3 years
h = operating hours
Tab. 46
10.2.4
Regular maintenance tasks
Cooling Oil: Change Interval

Duty cycles and ambient conditions are important criteria for the number and length of the change
intervals.
KAESER Service will support you in determining suitable intervals and provide information on
the possibilities of oil analysis.
Please observe national regulations regarding the use of cooling oil in oil-injected rotary screw
compressors.
60

ASD SFC
9_5714 06 E
10
Maintenance
10.3
Cooler: Cleaning or Renewing the Filter Mats
Check operating conditions and adjust intervals as necessary; log the results in table 47 for future
reference.
Maximum permissible oil change interval
[operating hours/year]
SIGMA FLUID
Favourable operating
conditions*
Unfavourable operat
ing conditions
PLUS / S-460
6 000**/2
4 000/1
MOL
3 000/1
2 000/1
FG460/FG680
3 000/1
2 000/1
FGH
3 000/1
2 000/1
My operating condi
tions
* Cool to moderate ambient temperatures, low humidity, high duty cycle

** Changing intervals of >6000 operating hours are not permissible without an oil analysis.
Tab. 47
10.2.5
Cooling oil changing intervals
Regular service work

The table below lists necessary service tasks.
Only authorized KAESER Service Technicians should carry out service work.
Carry out service tasks punctually taking ambient and operating conditions into account.
Interval
Service task
Up to 12,000 h
Check the valves
Up to 12,000 h, at the lat Check the drive motor and fan motor bearings.
est every 3 years
Up to 36,000 h, at the lat Check hose lines
est every 8 years
h = operating hours
Tab. 48
Regular service work
10.3
Cooler: Cleaning or Renewing the Filter Mats

The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the
components is no longer ensured.
Material
Precondition
9_5714 06 E
Filter mats:
Warm water and household detergent
Spare parts (as required)
The machine is switched off.

ASD SFC
61
Fig. 22
10
Maintenance
10.4
Control Cabinet: Clean or Replace the Filter Mat.
Filter mat for the air and oil cooler

1
Filter mat
No tools are needed to remove the filter mat.

1. Carefully remove the filter mat from the retaining frame.
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. Carefully insert the filter mat in the retaining frame.
10.4
Control Cabinet: Clean or Replace the Filter Mat.
Material
Warm water and household detergent

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

The machine has cooled down.
62

ASD SFC
9_5714 06 E
Fig. 23
10
Maintenance
10.5
Cooler Maintenance
Control cabinet ventilation grill

1
2
Ventilation grill
Filter mat
Frequency-controlled machines (SFC) have ventilation grills and filter mats in both the machine and
the frequency converter control cabinets. Maintain all filter mats at the same time.
1. Carefully remove the ventilation grill and take out the filter mat.
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Replace the filter mat if cleaning is not possible or if the change interval has expired.
4. Lay the filter mat in the frame and latch in the ventilation grill.
10.5
Cooler Maintenance
Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air. The
frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.
Material
Precondition
Brush and vacuum cleaner.

Breathing mask (if required).
9_5714 06 E

ASD SFC
63
Fig. 24
10
Maintenance
10.6
Heat Recovery System Maintenance
Cleaning the cooler

1
2
Cooler
Brush
Cleaning the cooler

Do not use sharp objects to clean the cooler. It could be damaged.
Avoid creating clouds of dust.
Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
Heavy and stubborn contamination should be removed by a KAESER Service Technician.
Check the cooler for leaks
Can cooling oil be seen to be leaking?
Is a cooler leaking?
Have the defective cooler repaired immediately by KAESER Service.
10.6
Option W1/W2/W3
Heat Recovery System Maintenance
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is dependant
on the characteristics of the heat transfer medium.
Monitor the pressure in the heat transfer medium to detect any pressure drop.
10.6.1
Option W1
External heat recovery
Have the external heat recovery system checked annually by KAESER Service.
64

ASD SFC
9_5714 06 E
10.6.2
Precondition
10
Maintenance
10.7
Air Filter Maintenance
Option W2/W3
Internal heat recovery
Leakage
Pressure in the cooling oil circuit is generally higher than that in the heat recovery system. If a leak
occurs, oil will run into the heat transfer medium.
1. Check the heat exchanger visually for leaks.
2. Have an authorised KAESER Service Technician check the heat exchanger for internal leaks at
least once a year.
Contamination
Have an authorised KAESER Service Technician clean the heat exchanger as soon as a pressure
drop in the heat transfer medium is detected.
10.7
Air Filter Maintenance

Do not clean the air filter element with liquids.
Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress the pressure system and cause damage to the machine.
Material
Precondition
Replacement part
Fig. 25
Air filter maintenance

1
2
3
9_5714 06 E
Nut
Nut
Backplate

ASD SFC
4
5
Air filter element

Cover
65
10
Maintenance
10.8
Motor Maintenance
Opening the air filter housing

1. Undo the nuts 1 fixing the cover 5 to the side panel and take out the complete filter.
2. Unscrew the nut 2 and remove the backplate 3 .
Clean the air filter element by tapping.
Tap the element at the front a number of times with the palm of the hand.
Cleaning the filter element with compressed air
Use dry compressed air at not more than 5 bar to blow dirt from the air filter cartridge from inside
to outside.
Closing the air filter housing
1. Clean all parts and sealing surfaces.
2. Insert the element 4 in the cover 5 and lay on the backplate 3 .
3. Use the screw and nut 2 to hold the housing together.
4. Insert the air filter housing in the side panel and secure by the cover 5 with the nuts 1 .
5. Close all access doors and replace all enclosure panels.
6. Switch on the mains disconnecting device and reset the maintenance interval counter.
10.8
Motor Maintenance
The drive motor bearings are permanently greased. Subsequent greasing is not necessary.
Drive motor
Have the motor bearings checked by the KAESER Service Technician.
Fan motor
Have the motor bearings checked by a KAESER Service Technician.
10.9
Checking the Coupling

A defective coupling is recognisable by:
noisy running,
surface cracks,
colour change.
WARNING
Danger of injury from rotating coupling!
Never switch the machine on without the safety screen in place over the coupling.
66

ASD SFC
9_5714 06 E
10
Maintenance
10.10 Checking the Pressure Relief Valve
Fig. 26
Checking the coupling

1
2
Safety screen
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

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

In order to check the pressure relief valve, the machine's working pressure is raised above the acti
vating pressure of the valve.
Blowoff protection and air system pressure monitoring are switched off during the test.
Follow the detailed description of this procedure in the SIGMA CONTROL operating in
structions.
Never operate the machine without a fully functioning pressure relief valve.
Precondition
9_5714 06 E
The machine is switched off.

Password level 4 is activated.

ASD SFC
67
10
Maintenance
10.11 Checking the Excess Temperature Safety Shutdown Function
WARNING
The pressure relief valve blows off.
Excessive noise is caused when the pressure relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air.
Close all access doors; replace and secure all removable panels.
Wear ear and eye protection.
Abort the test if the working pressure rises 10% above the activating pressure of the valve.
1. Close the user's shut-off valve between the machine and the air system.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Observe the display of pressure on SIGMA CONTROL and call up the test function.
4. Stop the test as soon as the pressure relief valve blows off or working pressure rises to 10 %
above the activating pressure of the pressure relief valve.
5. If necessary, vent the machine and replace the defective pressure relief valve.
6. Deactivate the test function.
7. Open the user's shut-off valve between the machine and the air system.
10.11
Checking the Excess Temperature Safety Shutdown Function

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

The oil level can be seen through a window in the front access door.
Precondition
68
The machine has been running at least 5 minutes under LOAD.

ASD SFC
9_5714 06 E
10
Maintenance
10.13 Venting the Machine (depressurizing)
Fig. 27
Checking the cooling oil level

1
2
3
Minimum oil level

Maximum oil level
Optimum level
Check the oil level with machine running.

Result
10.13
Top up when the indicator shows minimum level.
Venting the Machine (depressurizing)

The machine must be isolated from the air system and completely vented before undertaking
any work on the pressure system.
The oil circulation vents automatically as soon as the machine is stopped.
Venting takes place in three stages:
Material
Precondition
Isolate the compressor from the air system.
Vent the oil separator tank.
Manually vent the air cooler.
The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.
The power supply disconnecting (isolating) device is switched off,
the disconnect device is locked in the off position,
a check has been made that no voltage is present.
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
9_5714 06 E

ASD SFC
69
10
Maintenance
10.13 Venting the Machine (depressurizing)
Fig. 28
Venting the machine

1
2
3
6
Hose coupling (air cooler venting)

Pressure gauge
Hose coupling (oil separator tank venting)
Male hose coupling
7
A
B
8
Shut-off valve
Shut-off valve open
Shut-off valve closed
Maintenance hose
Isolate the machine from the air system.

Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.
Venting the oil separator tank

WARNING
Escaping oil mist is damaging to health.
Do not direct the maintenance hose at persons while venting.
Do not inhale the oil mist.
Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read zero?
Make sure that the shut-off valve is closed or that the complete air system is vented.
With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
Slowly open the shut-off valve 7 to release pressure.
Disconnect the male hose fitting 6 and close the shut-off valve 7 .
If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or the section from the shut-off valve to the minimum pressure/
check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
70

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Maintenance
10.14 Topping up the Cooling Oil
2. Slowly open the shut-off valve 7 to release pressure.

3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
10.14
Topping up the Cooling Oil

Material
Precondition
Fig. 29
Topping up the Cooling Oil

1
2
3
4
5

Pressure gauge
Oil filler with plug
Cooling oil level indicator
6
7
A
B
8
Male hose coupling

Shut-off valve
Shut-off valve open
Maintenance hose
1. Vent the machine as described in section 10.14.1.

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

The oil circulation vents automatically as soon as the machine is stopped.
Venting takes place in three stages:
9_5714 06 E
Isolate the compressor from the air system.
Vent the oil separator tank.
Manually vent the air cooler.

ASD SFC
71
10
Maintenance
10.14 Topping up the Cooling Oil
WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
Isolate the machine from the air system.
Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.
Venting the oil separator tank

WARNING
Escaping oil mist is damaging to health.
Do not direct the maintenance hose at persons while venting.
Do not inhale the oil mist.
Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read zero?
Make sure that the shut-off valve is closed or that the complete air system is vented.
With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
Slowly open the shut-off valve 7 to release pressure.
Disconnect the male hose fitting 6 and close the shut-off valve 7 .
If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or the section from the shut-off valve to the minimum pressure/
check valve.
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
10.14.2
Topping up with cooling oil and trial run

Topping up the cooling oil
A sticker on the oil separator tank specifies the type of oil used.
CAUTION
The machine could be damaged by unsuitable oil.
Never mix different types of oil.
Never top up with a different type of oil to that already used in the machine.
1. Slowly unscrew the filler plug 4 .
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Maintenance
10.15 Changing the Cooling Oil
2. Top up to bring the oil to the correct level.

3. Replace the filler plug's sealing ring if necessary and screw the plug into the filler neck.
Starting the machine and carrying out a trial run
1. Close all access doors; replace and secure all removable panels.
3. After about 10 minutes, check the oil level again and top up if necessary.
4. Switch off the machine and visually check for leaks.
10.15
Changing the Cooling Oil

The machine must be isolated from the compressed air network and completely vented before
undertaking any work on the pressure system.
Drain the oil completely from the following components:
Oil separator tank
Oil cooler
Airend
Internal heat recovery system (option W1/W2/W3)
Always change the oil filter and oil separator cartridge when changing the oil.
Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to
adjust the airend discharge temperature to suit operating conditions.
Compressed air helps to expel the oil. This compressed air can be taken either from the compressor
itself or from an external source.
An external source of compressed air is necessary in the following cases:
Material
The machine is not operational.
The machine is to be restarted after a long period of standstill.
Cooling oil
Cooling oil receptacle
WARNING
There is risk of burns from hot components and oil.
Wear long-sleeved clothing and gloves.
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10
Maintenance
Fig. 30
Changing the cooling oil, oil separator tank

1
2
3
4
5
6
7

Pressure gauge
Oil filler port with plug
Cooling oil level indicator
Male hose fitting
Shut-off valve
Changing the oil with internal pressure
A
B
8
9
10
11
Shut-off valve open

Maintenance hose
Hose coupling (oil drain)
Shut-off valve (venting line)
Shut-off valve (oil drain)
Changing the oil using an external compressed

air source.
Machine has been running at least 5 minutes un The power supply disconnecting device is switch
der LOAD.
ed off.
The machine is fully vented, the pressure gauge The disconnecting device is locked in the off po
sition.
on the oil separator tank reads 0 bar.
A check has been made that no voltage is
1. Close the shut-off valve 10 in the venting
present.
line.
The machine is fully vented, the pressure gauge
2. Start the machine and watch the oil separator
on the oil separator tank reads 0 bar.
tank pressure gauge 2 until it reads 35 bar.
An external source of compressed air is available.
3. Switch off and lock out the power supply dis
connecting device and check that no voltage 1. Close the shut-off valve 10 in the venting
line.
is present.
4. Wait at least 2 minutes to allow the oil to flow 2. With the shut-off valve closed, insert the male
hose fitting 6 into the hose coupling 3 .
back to the separator tank.
3. Connect the maintenance hose to the exter
nal air supply.
4. Open the shut-off valve 7 until the pressure

gauge on the oil separator tank reads 35 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
Draining the oil from the separator tank
1. Have an oil receptacle ready.
3. Place the end of the maintenance hose in the oil receptacle and secure it in place.
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Maintenance
4. Open the shut-off valve 11 .

5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Draining the oil from the cooler
Fig. 31
Changing the cooling oil, oil cooler

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

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.
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75
10
Maintenance
Draining the oil from the airend
Fig. 32
Changing the cooling oil, airend

1
2
3
Compressed air outlet on airend

Hose coupling (oil drainage)
Shut-off valve
4
5
Safety screen
Coupling

4. Open shut-off valves 3 and 7 (Fig. 30)
5. Remove the coupling safety screen 4 and turn the coupling 5 by hand at least five revolutions
until all the oil has run out.
6. Fit the safety screen again.
Result
The cooling oil is drained from the airend.

A small amount of cooling oil may flow back into the oil cooler and oil separator tank as a result of
turning the coupling.
Remove this by repeating the steps for draining oil from the separator tank and oil cooler.
Option W1W3
Draining the oil from the heat recovery system

Shut-off valves are provided for draining the oil from the heat recovery system. In machines equipped
with an external heat recovery system (option W1), the oil is drained from the appropriate point.
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Maintenance
10.16 Changing the Oil Filter
Fig. 33
Changing the cooling oil, heat recovery system

1
2
3
Hose coupling
Thermostatic valve
Shut-off valve

2. Insert the male hose fitting 6 (Fig. 30) in the hose coupling 2 .
4. Open the shut-off valves 3 and 7 (Fig. 30) and allow the oil to drain completely.
Filling with oil
1. Open the filler plug 4 (Fig. 30) slowly.
2. Fill with cooling oil.
3. Check the filler plug and ring seal for damage and screw the plug back in again.
Starting the machine and carrying out a trial run
1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
5. Switch off the machine and check visually for leaks.
Dispose of used oil in accordance with environmental protection regulations.
10.16
Changing the Oil Filter

Material
Replacement part
Cooling oil container
Precondition

The machine is fully vented, the pressure gauge on the oil separator cartridge reads 0 bar.
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10
Maintenance
10.17 Changing the Oil Separator Cartridge
WARNING
There is risk of burns from hot components and oil.
Wear long-sleeved clothing and gloves.
Fig. 34
Changing the oil filter

1
2
Oil filter
Direction to unscrew
Changing the oil filter

1. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi
ronmental protection regulations.
2. Lightly oil the new filter's O-ring.
3. Turn the oil filter clockwise by hand to tighten.
Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a test run
4. After about 10 minutes, check the oil level again and top up if necessary.
5. Switch off the machine and visually check for leaks.
10.17
Changing the Oil Separator Cartridge

The oil separator cartridge cannot be cleaned.
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Maintenance
The life of the oil separator cartridge is influenced by:
Material
contamination in the air drawn into the compressor,
adherence to the changing intervals for:
cooling oil
oil filter
air filter
Replacement part
Cleaning rags
Precondition

The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar.
Fig. 35
Changing the oil separator cartridge

14
15
16
17
Cover
Dirt trap
Air pipe
Fixing screws
19
20
21
23
Nut (self locking)

Fitting
Gasket
Changing the oil separator cartridge

1. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
2. Unscrew the nut 19 and turn the air pipe 16 to one side.
3. Remove the cover fixing screws 17 and carefully remove the cover 14 .
4. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of according
to environmental protection regulations.
5. Clean all sealing faces.
6. Insert the new oil separator cartridge with gaskets and screw down the cover.
7. Renew the O-ring and strainer in the dirt trap 15 .
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10
Maintenance
8. Attach the air pipe to the cover 14 with a new, self-locking nut.
9. Replace and tighten all fittings.
Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a test run
4. Stop the machine after 10 minutes and visually check for leaks.
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Maintenance
10.18 Document maintenance and service work.
10.18
Document maintenance and service work.

Machine number:
Enter maintenance and service work carried out in the list.
Date
Tab. 49
9_5714 06 E
Maintenance task carried out
Operating hours
Signature
Logged maintenance tasks

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81
11
11.1
Note the Nameplate
11 Spares, Operating Materials, Service

11.1
Note the Nameplate

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

KAESER consumable parts and operating materials are all genuine KAESER parts. They are selected
for use in KAESER machines.
WARNING
Personal injury or damage to the machine may result from the use of unsuitable spare parts or
operating materials.
Unsuitable or poor quality consumable parts and operating materials may damage the machine or
impair its proper function.
In the event of damage, personal injury may result.
Use only genuine KAESER parts and operating materials.
Have an authorized KAESER Service Technician carry out regular maintenance.
Machine
Name
Tab. 50
Quantity
Number
Air filter element
1250
Filter mat (cooler)
1050
Filter mat (control cabinet)
1100
Oil filter
1200
1450
Cooling oil
1600
Quantity
Number
1150
Consumable parts
Frequency Converter
Name
Filter mat (control cabinet)
Tab. 51
Consumable parts for the frequency converter
11.3
SIGMA AIR SERVICE

SIGMA AIR SERVICE offers:
82
authorised service technicians with KAESER factory training,
increased operational reliability ensured by preventive maintenance,
energy savings achieved by avoidance of pressure losses,

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11.4
Service Addresses
optimum conditions for operation of the compressed air system,
the security of genuine KAESER spare parts,
increased legal certainty as all regulations are kept to.
Why not sign a SIGMA AIR SERVICE maintenance agreement!

Result
11.4
Your advantage:
lower costs and higher compressed air availability.
Service Addresses
Addresses of KAESER agents are given at the end of this manual.
11.5
Spare Parts for Service and Repair

With the help of this parts list you can plan your material requirement according to operating conditions
and order the spare parts you need.
Make sure that any service or repair tasks not described in this manual are carried out by
an authorized KAESER Service Technician.
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84
11
11.5

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11.5

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12
12.1
Putting Out of Operation
12 Decommissioning, Storage and Transport

12.1
Putting Out of Operation

This is necessary under the following circumstances:
The machine is temporarily not needed.
The machine is to be moved to another location.
The machine is to be scrapped.
Temporarily putting out of operation

Precondition
The machine can be started at regular intervals.

Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protection
against corrosion.
Putting out of operation for a longer period
Precondition
Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the mains disconnecting device,
check that no voltage is present.
Machine fully vented (no pressure).
1. Allow the machine to cool down completely.
2. Disconnect all air and electrical connections.
12.2
Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Consult an authorized KAESER Service agent for advice on packing for sea or air transport.
Material
Desiccant
Plastic sheeting
Wooden transport crate
Precondition
The machine is decommissioned.

Machine is dry and cooled down.
1. Place sufficient desiccant (silica gel or similar) inside the machine cabinet.
2. Wrap the machine in plastic sheeting.
12.3
Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator tank.
Frozen moisture can damage components, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and commissioning.
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12.4
Transporting
CAUTION
Moisture and frost can damage the machine.
Prevent ingress of moisture and formation of condensation.
Maintain a storage temperature of >0 C.
Store the machine in a dry, frost-proof room.
12.4
12.4.1
Transporting
Safety
Weight and centre of gravity determine the most suitable method of transport. The centre of gravity
is shown in the drawing in chapter 13.2.
Precondition
Transport only by fork truck or lifting gear with personnel trained in the safe transport of goods.
Make sure the danger zone is clear.
12.4.2
Precondition
Fig. 36
Transporting with a forklift truck

The forks are fully under the machine.
Transporting with a forklift truck

Drive the forks completely under the machine or palette and lift carefully.
12.4.3
Transporting with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fully under the machine.
The slings may not bear on the side of the machine cabinet.
Examples of unsuitable fixing points:
Precondition
Pipe sockets
Flanges
Attached components such as cyclone separators, condensate drains or filters
Rain protection covers
The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the machine cabinet.
9_5714 06 E

ASD SFC
87
Fig. 37
12
12.5
Disposal
Transporting with a crane

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

1. Completely drain the cooling oil from the machine.
2. Remove used filters and the oil separator cartridge.
3. Hand the machine over to an authorized disposal expert.
Components contaminated with cooling oil must be disposed of in accordance with local
environment protection regulations.
Machines with refrigeration dryers
The sealed refrigerant circuit still contains both refrigerant and oil.
Refrigerant and oil must be drained and disposed of by an authorized body.
88

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9_5714 06 E
13
Annex
13.1
Pipeline and instrument flow diagram (P+I diagram)
13 Annex
13.1
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89
90
13
Annex
13.1

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Annex
13.1

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91
92
13
Annex
13.1

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Annex
13.1

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93
94
13
Annex
13.1

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13.2
9_5714 06 E
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Annex
13.2
Dimensional Drawing
Dimensional Drawing

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96
13
Annex
13.2
Dimensional Drawing

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Annex
13.2
Dimensional Drawing

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13.3
98
13
Annex
13.3
Electrical Diagram
Electrical Diagram

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Annex
13.3
Electrical Diagram

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100
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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101
102
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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104
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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106
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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108
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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109
110
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

ASD SFC
111
112
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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114
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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116
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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118
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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120
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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122
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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124
13
Annex
13.3
Electrical Diagram

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9_5714 06 E
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Annex
13.3
Electrical Diagram

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126
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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128
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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130
13
Annex
13.3
Electrical Diagram

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Annex
13.3
Electrical Diagram

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132
13
Annex
13.3
Electrical Diagram

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Service Manual

KAESER KOMPRESSOREN GmbH

Regarding this document

Safety and Responsibility

Design and Function

Service Manual Screw Compressor

Installation and Operating Conditions

Fault Recognition and Rectification

Service Manual Screw Compressor

Spares, Operating Materials, Service

Decommissioning, Storage and Transport

Service Manual Screw Compressor

Service Manual Screw Compressor

Maximum relative humidity .........................................................................................................

Service Manual Screw Compressor

Service Manual Screw Compressor

The levels of danger and their meaning .....................................................................................

Service Manual Screw Compressor

Service Manual Screw Compressor

Regarding this document

Using the Document

1 Regarding this document

Using the Document

Certificate of acceptance / operating instructions for the pressure vessel.

Manufacturer's declaration / declaration of conformity in accordance with applicable directives.

Missing documents can be requested from KAESER.

Symbols and Identification

Service Manual Screw Compressor

Regarding this document

Symbols and Identification

Always read and comply with warning instructions.

Death or serious injury may result

Warns of an imminent threat of danger

WARNING Warns of possible danger

Death or serious injury are possible

The levels of danger and their meaning

Other instructions and symbols

This bullet is is placed by lists of actions comprising one stage of a task.

Here, your attention is drawn to further topics.

Service Manual Screw Compressor

above the cooler,

on the rear of the machine.

Enter the data from the nameplate here as a reference:

Filter monitoring option package

Cooling-air filter mat

Transformer power supply

Prepared for heat recovery

Heat recovery T=25 K

Heat recovery T=55 K

Service Manual Screw Compressor

Minimum cut-in tempera

Typical airend discharge

Maximum airend dis

Maximum altitude AMSL*

Permissible ambient tem

Cooling air temperature

Inlet air temperature [C]

Maximum relative humidi

Service Manual Screw Compressor

Maximum relative humidity

Inlet air temperature [C]

Inlet aperture Z see fig

Pressure relief valve activating pressure (50 Hz)