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SERVICE MANUAL

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3. 1 Shutoff valve 4 Threaded plug 8 Maintenance hose A closed topping off oil 9 Oll level indicator B open 5 separtor tank 11 Oil drain shutoff valve 2 Pressure gauge 6 Plug in nozzle 12 Hose coupling 3 Hose coupling Ball valve rz Remove cover panels 5 6 and 9 see chapter 9 2 9 13 1 Draining the oil using external pressure source Draining the oil on the oil separator tank rz Insert the nipple with attached hose 6 ball valve closed in the hose coupl ing 3 on the oil separator tank 5 rx Apply separate pressurization to the attached hose Pressurize the oil separator tank 5 by slowly opening the ball valve 7 until the pressure gauge 2 on the oil sep arator tank 5 shows approximately 3 bar rz Remove the nipple with attached hose 6 from the hose coupling 3 on the oil separ ator tank 5 rz Prepare a clean container to catch escaping oil The container must be large enough to hold the total oil content of the compressor package see chapter 1 7 rz Insert the nipple with attached hose 6 ball valve closed in the hose coupl ing 12 on the oil separator tank 5 9 13 2 9 13 3 KAESER COMPRESSORS Maintenance rz Hang the attached hose hose into the container and secure Open the shut off valve 11 rz Slowly open the ball valve 7 The remaining pressure in the oil circulation forces out the oil When air escapes close the ball
4. 7 29 7 8 1 Pour a small quantity of oil into the air inlet port 7 29 7 8 2 Running the compressor package in idle 7 29 uio 8 30 Patel d 8 30 600 8 1 bt od oa bb ade 8 30 DIGIVIACCOMUMONE MERERI TE ev 8 2 Emergency Stop PUSHOUTION 078 5 IER EA 8 30 8 3 FUNCION KOVS ern Br APG ee we 8 31 Light emitting diodes and plain text display 8 31 8 3 2 Compressor Package ON OFF 8 32 8 4 Acknowledgement of Alarms 8 32 8 5 Acknowledgement of Service 5 8 33 8 6 Faults Possible cause Remedy 8 34 8 7 Working temperature too high 8 34 8 7 1 Motor overload protection relay trips 8 34 8 7 2 Compressor runs but does not reach pressure 8 35 8 7 3 0 01 01 oer 8 35 8 74 frequent switching between loa
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15. 8 5 Operating temperature approx 75 100 related to the gauge working pressure and climatic conditions such as humidity in the air and ambient temperature eee es oe 3040 Drawings Dimensional drawing T9052 02 19443 01 P amp lflow diagram FDSD141STL 0130 00 Pipework and instrument flow diagram Electrical diagram SDSD171 L 01003 02 Sound Pressure Level Operational state of the compressor unit Technical Specification bar C kg Full load the compressor unit runs at rated speed rated pressure rated capacity Setting up conditions Free field measurement Measurement to CAGI PNEUROP 8 2 3 Sound Pressure Level 70 Motor Drive motor Rated 6 E EUER bowie tad duds 90 Rated Speed ecb eid bd eee 1500 CASS 4 4 00 wid see Ane b aad ds IP 55 Fan motor eA 2 5 Rated x4zavimerdd 1000 0355 54 dB kW kW 1 4 1 5 1 6 1 7 KAESER Power Supply see chapter 6 3 for further details Mains voltage 400 10 V3 PE p 50 Hz mains fusing Slowblow
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19. 1 5 1 10 weet aces Exc MER 1 5 2 581618 5 bat eee I Id 2 8 2 1 Explanation of Symbols and References 2 8 2 2 General Safety Instructions 2 9 2 3 Elec real Sale toa vers cen od ed dena ere ae apa 0 t 2 10 2 4 Pe 2 10 2 5 Compressed Air Installation 2 10 2 6 Environmental ProtecllOfi 2 ain 3 dew 2 ae OS Bade 0 8 ano Vb ute dees 2 11 9 AGCHClal 3 12 3 1 600 USC exque 2 ted od 3 12 3 2 INC OMeCt E Lune 12 3 3 Compressed Air Treatment 3 12 3 4 i eT 3 12 3 5 Accompanying Documents 3 12 tee ed ded 4 13 4 1 Transport INSTIUCHIONS lt lt 2 4 13 4 2 cim ACN NOLO RH Wade ated ach ed we antec ds Vets alates ae Dede attach eek a eta 4 13 4 3 MCN 4 14 5 Technical Description 4 04504445 5 15 5 1
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23. 19 5 6 KAESER e lf the air main pressure rises to the upper switching point and the running period has already expired the compressor package is switched off after the run on period has expired 2 e lf the air main pressure rises to the upper switching point before the running period has expired then the pressure decay time of the previous switching cycle is taken as the criterium for the selection of the operating mode lf the pressure decay time was longer than the period set for the idle standstill period the compressor package is switched to standstill after the run on period has expired 3 If the pressure decay time tpaecay was shorter than the period set for the idle stand still period the idle mode is selected 4 that is the inlet valve closes and the com pressor is vented with running motor When the running period expires the com pressor package switches to standstill only after the run on period has also expired 5 VARIO Control Mode Functional description The idle period is automatically lengthened or shortened by the variable idle control in rela tion to the number of motor starts The number of motor starts during the preceding hour are measured A high switching frequency leads to longer idle periods A low switching frequency leads to shorter idle periods 5 20 KAESER COMPRESSORS Installation 6 6 1 Installation Installation Requirements
24. 30 KAESER COMPRESSORS 8 3 1 8 3 2 Function keys ON key I OFF key 0 Timer ON OFF key Remote ON key Load idle key gt 6 44 6 Light emitting diodes and plain text display 9 ON OD Operation SIGMA CONTROL Menu scroll DOWN key Menu scroll UP key Escape key Return key Info event key Acknowledge reset key 12 Four line display 13 Alarm LED 14 Communication alarm LED 15 Warning maintenance LED 16 Power ON LED to controller Load LED Idle LED Compressor ON LED Remote ON LED Timer ON LED 8 31 8 4 8 5 Operation Compressor Package ON OFF Do not switch the the compressor package on and off with the main switch The compressor must always be switched ON and OFF with keys 1 and 2 Local ON rz Switch on the main switch The controller carries out a self test The self test sequence 16 visible in the display 12 Afterwards the green LED 16 illuminates permanently rz Press the ON key 1 LED 19 illuminates The compressor status is indicated by LEDs 17 and 18 If LED 19 is illuminated and both LEDs 17 and 18 are extinguished the compressor package is at standstill but on duty The compressor package can start at any moment Local OFF rz Press the OFF key 2 LED 19 extinguishes t Switch off and lock out the main switch See chapter 2 3 for details of the main switch
25. DUAL Control AAA AAS AN 4 2 P min 4 1 Q 5 3 Time In DUAL Control mode combined idle and start stop the compressor normally runs at full load idle or standstill The controller regulates the compressor package between load and idle If the compressor package runs in idle for longer than the preset period 1 to 2 for example 6 min the drive motor is stopped completely 2 When the lower switching point Pmin 3 is reached the compressor package is automatically started again Pressure rises to the upper switching point Pmax 4 and the compressor package switches to idle If the pressure falls again to for example 5 within a shorter period 4 to 5 then the compressor is automatically switched from idle to load The idle period is dependent on the maximum motor starting frequency 5 18 KAESER QUADRO Control min Full load Idle Standstill Pressure gt Motor power gt Time iie gt ES orn Running period 5 1 prm standstill period period gt sje gt Stop point for the running period or idle standstill period Pmax upper switching point Pmin lower switching point brie pressure rise t
26. Ensure the equipment is dry and cover in plastic sheeting Protect the interior with suffi cient quantities of desiccant silica gel or similar Storage for longer than 12 months Carry out the following additional maintenance tasks before putting into operation Change the cooling fluid filter see chapter 9 11 rz Change the fluid separator cartridge see chapter 9 14 Change the cooling fluid see chapter 9 13 rz Have the motor bearings checked by an authorised KAESER service technician Storage for longer than 3 years After 3 years at the latest the complete technical condition of the equipment must be checked before start up Starting up the equipment without a full inspection can lead to dam age r Have the the start up carried out by an authorised KAESER service technician 4 14 5 1 5 2 5 3 KAESER Technical Description Principle of Compression The stationary compressor package is fitted with a single stage oil injected airend Two rotors the driven male rotor and the female rotor both mounted in roller bearings are fitted in the airend As the rotors rotate air is drawn into the upper side through the inlet port and is compressed on the lower side The oil that is injected into the lower side ab sorbs heat generated by compression prevents metallic contact between the rotors seals the rotors and the housing from each other and also lubricates the roller bearings The
27. gl class 224 A Power supply cable cross section 4x120 mm CU multicore cable CUNEN TOW eb Ed CHE D e OS 179 A Pressure Relief Valve Activating pressure 11 5 bar Installation Requirements Max height above sea level 1000 m consult with the manufacturer before installing at greater altitudes Min ambient temperature C Max ambient temperature 40 Min cooling air inlet air temperature C Max cooling air inlet air temperature 40 Air inlet opening 2 m Exhaust air for solution A see chapter 6 1 Forced ventilation with exhaust 27500 3 at 100 Pa Exhaust air for solution B see chapter 6 1 Exhaust air used for space heating ducbW es etre dens 975 975 mm Oil Capacities Ol GAD ACKY dee 6 ido m 72 After oil change or after long period of storage Amount required to top up the airend 4 Difference in oil volume between minimum and maximum levels TOD OMVOU ss cima s 13 1 8 1 8 1 1 8 2 1 8 3 KAESER Recommended Cooling Fluid Cooling and lubrication are decisive factors for reliable
28. It is possible that the separator cartridge will have to be changed because of existing cool ing fluid deposits that detach themselves after changing the type of cooling fluid This one off additional requirement is caused by the cleaning effect of the new cooling fluid Drive Motor Service Interval Greasing the bearings 2000 h cue auctae seb CER RECS 35 g operating hours Always use ESSO Unirex high temperature grease for the bearings Bearing damages caused by the use of other brands of grease are excluded from the war ranty ESSO Unirex N3 part numbers 100 g part No 9 0915 0 400 g part No 6 3234 0 Renew the drive motor bearing Under normal operating conditions after 36000 h ambient temperature up to 25 C Under unsuitable operating conditions after 20000 h ambient temperature up to 40 aL trie HALOS aller s euo sos iur ien 8 years service hours Renew the fan motor bearing Under normal operating conditions after 12000 h ambient temperature up to 25 C Under unsuitable conditions after 6000 h ambient temperature up to 40 C but at the latest after 3 years service hours Dimensional Drawing see following page E WERT mee m
29. 2 3 2 4 2 5 KAESER COMPRESSORS Safety 6 Do not mix cooling oils of different types 6 The operating temperature stipulated must be kept to and checked constantly to avoid condensate in the oil circulation If maintenance work is carried out on any part of the oil circulation system top up the oil in the oil separator tank to the maximum level afterwards run the compressor for a short period and keep it under constant observation Check the oil level again and top up with oil to replace the oil taken up by the piping and the cooling system e Use the filter cartridge of the oil separator tank only as long as the pressure drop across the filter is less than the 1 bar specified Check constantly e his machine is not explosion proof It may not be operated in areas in which specific requirements with regard to ex plosion protection are applied These are for example the requirements for specified use in hazardous explosive environments according to the 94 9 EU ATEX Directive Electrical Safety The electrical installation of the compressor package must conform to the requirements of European Standards EN 1012 1 and EN 60204 1 The regulations of the local electricity authority must also be complied with For this reason the following measures must be carried out by the user to ensure the safe operation of the compressor package e Compressor packages fitted with a drive motor of 3 kW or above and a curren
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33. Acknowledgement of Alarms If an alarm occurs the compressor package is shut down immediately and the red LED 13 on SIGMA CONTROL flashes The bottom line in the display 12 shows the actual fault causing the alarm A list of alarms that may occur during operation is included in the SIGMA CONTROL service manual rz Remove the fault rz Acknowledge alarm with the reset key 11 LED 13 extinguishes The compressor package is now ready to start again If the compressor was shut down with the EMERGENCY STOP push button then reset by rotating the latched pushbutton in the direction of the arrow before acknowledging the alarm 8 32 8 6 KAESER COMPRESSORS Operation Acknowledgement of Service Messages When maintenance is due the yellow LED 15 on SIGMA CONTROL flashes Maintenance due is shown in the display 12 A list of service messages that may occur during operation 15 included in the SIGMA CONTROL service manual rz Carry out the maintenance work rz Acknowledge service message with the reset key 11 LED 15 extinguishes When the respective maintenance has been carried out the remaining interval period programmed interval until the next maintenance is due must be reset Detailed information on resetting service counters is to be found in the service manual for SIGMA CONTROL 8 33 KAESER COMPRESSORS Operation Faults Possible cause Remedy N The removal of faults that are not e
34. No air receiver installed or receiver too small to function correctly as a buffer Diameter of pipe connecting compres sor and air receiver too small Minimum pressure check valve not air tight Reduced flow to the air main connec tion Pressure relief valve blowing off Possible cause Machine does not vent in idle running Oil separator cartridge clogged Minimum pressure check valve not open Pressure relief valve not suitable for the compressor s pressure range Oil in the package Possible cause Maintenance hose or coupling still plugged into the air receiver connec tion point Pressure relief valve blowing off Oil running out of air filter Air receiver hose coupling loose Oil cooler leaking Cooling fluid consumption too high Possible cause Unsuitable cooling fluid used Operation Remedy Refer to a KAESER service agency for advice on correct air receiver size The diameter of the air pipe should not be less than that of the air connection Have the valve inspected by an autho rised KAESER service agent Check filter elements for clogging Open any partially opened valves fully Defrost any frozen air lines Replace defective pressure regulator Remedy Ensure that the venting line ball valve is open Have an authorized KAESER Service Technician check the control line inlet valve and control venting valve Check the pressure drop and change the cartridge if necessa
35. SIGMA FLUID PLUS 200 Part No 9 1454 2 SIGMA FLUID FGL SIGMA FLUID FGL is a synthetic oil specially developed for use with rotary screw com pressors intended for the supply of compressed air coming into occasional contact with foodstuffs This cooling fluid complies with USDA 1 and is approved for the manufacture of foods tuff wrapping materials for meat and poultry processing and for other foodstuff processing applications KAESER SIGMA FLUID FGL has the following properties e Viscosity to D 445 ASTM Test at 40 50 7 mm s e Viscosity to D 445 ASTM Test at 100 C 8 2 mm s e Flash point to D92 ASTM Test 254 C Cooling fluid part No SIGMA FLUID FGL 19 part No 9 1463 0 SIGMA FLUID FGL 208 part No 9 1462 0 1 9 1 10 KAESER Compatibility of KAESER cooling fluid All the KAESER cooling fluids mentioned above are comparable with mineral oil with regard to their material compatibility with paints sealants and hoses Never mix different types of cooling fluid Synthetic cooling fluids can attack polycarbonate oil trays For this reason we recommend metal oil trays Certain plastic parts in the compressed air supply may not be resistant to synthetic cooling fluid When changing the type of cooling fluid ensure that the fluid circulation system of the compressor package is completely drained before filling with the new fluid As far as poss ible remove any deposits in the cooling system
36. __ _______________________________ __________________ ME 6 70 6 a 70 2 4 10X2 9 70 4 70 4 6 8 XE XE TXC S9X 6 6LXC 81 6LXC 647 610 46 aY 60 4 6 610 8 610 61 6LX 6 10 8 6 10 4 8 8 8 1 coxz 9d gX 9d ZX 54 pueog 4 LZ 8 01 i 70 70 4 IY 2 6LX 6L0Xc 610 6LX il 0 75 0 TIX mE 201001050 1805 5 8040 435 3V c 8 esp seen 9 eas Porat 18 LP c0 0010 10505 sjndjng pJeoq Japuedxj 141 050 40558 4 2 JIn24rj 500113011 10 1 31013114 87 WE 8 01 A 89 4 1 2119 4 8 8 M8 AYZ M8 420 od 81X t 0d 8 8 6LX 67 TI 610 ev 610 610 4 6L0X 6LX 89 4 6LX 9 4 9 4 219 4 41 9 4 LL 9 4 90 4 21 90 4 I 90 4 3 90 4 cT 21 11 LT ox 01V 26 2070 Ajddns Japuedxy 0LW 6 8 21 Jasn aul 185 5 __ _______ ___
37. _____ _ ___ ____ __7 ____ 4 70 E0010 TLILOSQS sjndjng pJeoq Japuedx3 21100501 dN 11218 d N3JOSS33dl40M e o 050 40558 010 susypuweg 1 ar 413417 445 JV Jepuedx3j suoipun JoJow UP uoun 6 40 8811 4100 S4JIEJUOI 5 185 11285112 12 591 59 Ls tl ye V 11 LON 86 JU AWZ IV 042 xeu 201 86 e LL 0 6 8 5 GX 1 LL 01 6 8 5 7 50X 0 LL OL 6 8 4 9 5 7 c L 20X1 coL OLV 6 5114110 510 ELO 0 Jepuedx3 UP 710 OL OLY Jasn aul 185 5 __ ______ ___ lt _____ ___ gt _____ ___ _____ gt _____ ___ _____ ____ lt ____ __ ___ 000000 bunny a Z0 00L0 TLLLOSOS 5 8841 410 050 40558 4 sse wesbep yng 035 17 wswo weo T 51306003 33JJ OA 500113011 10 1 Buluuns Y ALOH abueso 5 pajeubisap uou VE 20 054 xeu ib xX 9 2 ZX
38. seus eame ____ _ 5 15 5 2 SHO WESChOUOM REM ML EE 5 15 5 3 Pipe and Instrument Flow Diagram Diagram 5 15 5 4 5 8 5 5 QUAD AO 0 5 19 5 6 VARIQ GCOnlrol MOE erates Bee ae oh 5 20 KAESER Chapter Page 9 nance deer cae hota 6 21 6 1 Installation Requirements 6 21 6 2 COMMCCUON 6 50 vate aside d eine adusta eV en 6 22 6 3 Electrical ConneclloD as occorre cen 5 PUPPES 6 22 7 edu 45440 65402 448 40114 54444148 uS dE 7 24 7 1 Points to be Noted before Initial Start up 7 24 7 2 Observe the following before starting 7 24 7 3 eau aus der od o aria ultus Eod dra 7 26 7 4 Direction Or Rotation 7 27 7 5 Setting up the Motor Overload Trip 7 27 7 6 Setting the Motor Overload Protection Switch 7 28 7 7 Setting the Air Main Pressure Threshold 7 28 7 8 Measures to be taken before Initial
39. 050 NIE 060 34055384 711 wew wes s ais VM b ueJbeig d aDpi jJe5 01816095 110 Q aJnssaJd jeuJaju ja3npsueJj Buiunseau aJnssaJg 7 65 Jal aJ 84055844 aJnssaJd Bulunseaw aJnssaJg 5 JOJEIIPU 18181 10 9 03 ES uleJP bundno 8504 6 110 979 B44 10 10 4 02 au 581 pue we 850 9 041403 7 31 472 pua asoy 29 18 8 12 abneb 34055944 19 JU3A BAJBA 3140 1046 02 JojeJedas 9 JUJA 6l 105495 00114 5 104110 81 105485 901 4015 Jld LS ju2A oJjuo9 21 914494 40429102 10 74 91220 Ll Jo DuoJM YI4IMS 84055914 7 410 1 1 17 asoy 181002 El Ue 81055940 1 JOJOW 9410 10 burjdnoo 8504 440 4NYS 9 Bnjd 10 Lc 191992 10 LL 4914 C 110 32 5 81550160 LOL 104291102 4510 4811 10 0 18414 2 5 181 041403 aJnjeJadua 0 6 Jal JY ee 5 17 KAESER
40. 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run N Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized rz Venting the compressor package see chapter 9 10 18 19 19 14 Cover 16 Air pipe 19 Self locking nut 15 Dirt trap 17 Hexagonal bolts 20 Union nut with copper pipe 18 Ring clamps 21 Gasket 23 Oil separator cartridge 25 Minimum pressure check valve rz Remove cover panels 5 6 and 9 see chapter 9 2 rz Loosen the union nuts 20 and lay the parts with the connections carefully to one side pull out the copper pipe at position 15 rz Unscrew the self locking nuts 19 on both ends of the air pipe 16 on the oil separ ator tank and the air cooler and remove the air pipe 16 KAESER COMPRESSORS Maintenance rz Remove the minimum pressure check valve 25 rz Unscrew the bolts 17 holding down the cover plate 14 e 1 Hexnut 2 Swivel mechanism rz Turn the hex nut 1 on the swivelling device 2 in the direction of the arrow until the cover 14 is slightly raised rz Swivel the cover 14 to one side When tightening the cover 14 to the oil separator tank take care that the hex nut 1 is turned until the cover sits flat on the gasket 21 This applies when the hex nut 1 can be turned by hand rz Take out the old oil sepa
41. Tensioning screw 2 Sealing ring holder 6 Self kocking nut 3 Sealing ring 7 Ring clamp halves 4 Self locking nut 8 Sleeve Ensure that the pipe 1 is free of burrs on the cut edge a and that the sealing surface b is clean and undamaged gt Slide the sealing ring holder 2 and the sealing ring 3 over the pipe 1 Insert the pipe 1 into the sleeve 8 without straining slide the sealing ring 3 with the sealing ring holder 2 up to the bevelled edge of the sleeve 8 Realign the pipe if necessary Lay the two halves of the ring clamp 7 over the sealing ring holder 2 and sealing ring 8 and tighten up to the s measurement see chapter 9 16 The s measure ment is a guide and may vary by up to 2 Tighten the tensioning screws 5 with the nuts 6 such that all tensioning screws can be just moved by hand when the compressor package is shut down Under full load all tensioning screws must be equally loaded Replace the self locking nuts 4 and 6 after loosening and tightening three times Flexible Pipe Connection Measurements The measurement s is a standard value and can vary by approx 2 dependent upon production Pipe outside dia Clamp outside dia Part No of the seal d in mm 5 in mm 9 17 KAESER COMPRESSORS Maintenance Record of Maintenance Work Serial number of the unit 10 10 1 10 2 KAESER Spare Parts and After Sales Service Service parts and expend
42. a current rating greater than 16 ampere must be installed with a lock able main isolating switch and main fuses The type of main switch used is dependent on the power consumption of the drive motor see chapter 1 4 for the value The type of protective power circuit breaker used is dependent on the starting characteristic of the drive motor 6 22 COMPRESSORS Installation fied to DIN VDE 0100 part 430 and 523 for an ambient temperature of 30 C For other operating conditions e g higher ambient tempera tures or longer supply lines over 50 m check and determine the cross section of the cable and the fuse ratings according to DIN VDE 0100 and local electricity authority regulations See chapter 1 4 for recommended cable cross sections and fuses The cross section of the supply cable and the fuse ratings are speci The compressor package can be operated over a rated voltage range of 380V to 420V at a tolerance of 5 without reduction in perform ance because of the wide voltage range of the winding fitted in the drive motor If the compressor is operated at a mains voltage other than 400V then the tappings on the control transformer must be changed to 5 for a mains voltage of 380V or 5 for a mains voltage of 420V 6 23 7 1 7 2 KAESER COMPRESSORS Initial Start Initial Start up Points to be Noted before Initial Start up Every compressor is given a test run in the factory and c
43. by an authorized KAESER Service agency after the maintenance interval see chapter 1 9 quoted has elapsed The bearing covers and or the end shields must be removed and the old grease disposed of according to environmental regulations when the motor bearings are changed Fan motor The bearings of the fan motor are permanently greased Have the bearings renewed by an authorized KAESER Service agency when the maintenance interval has elapsed see chapter 1 9 Coupling Visually check the coupling regularly and carefully when the operating hours quoted in the maintenance routine have expired see chapter 9 3 Pay attention to smooth running and surface cracks rz Remove cover panel 3 see chapter 9 2 rz Visually check the rotating coupling for smooth running rz Shutdown the compressor package see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor start eene 21 2 oc 1 Safety screen 2 Coupling 9 10 Maintenance rz Unscrew the safety screen 1 rz Rotate the coupling 2 by hand and check for damage If the coupling is damaged have it replaced by an authorised KAESER service agent rz Replace the safety screen 1 rz Close all access doors and fit all cover panels Checking the Pressure Relief Valve on the Oil Separator Tank To check the operating pressure of the pressure relief valve the
44. compressed air and oil mixture leaves the airend via the discharge port 22 9 pia LJ 1 4 5 1 Drive shaft 4 Male rotor 2 Olilinjection 5 Female rotor 3 Discharge port 6 Airinlet port Short Description The compressor airend is driven via a coupling from an electric motor An oil separator cartridge is fitted into the oil separator tank allowing a practically oil free compressed air supply The regulation of the compressor ensures that compressed air is generated within the set pressure limits A safety function protects the compressor package against failure of important systems by automatic shut down The fan ensures sufficient cooling air flow to the air cooled oil cooler and air cooler Pipe and Instrument Flow Diagram P amp I Diagram see following pages 5 15 om mea Twin sue weary 1 0 puo gt 050 00 N3HOSS3HdAOM weubelg 134 2145 191410 passauduio Construction and Operation 0 O 0 7 oc 5 16 Construction and Operation 0 O 0 7 oc TTE BENNETT MEE 00 0 0 11S1 10SQ 11
45. oy esa cenezess ameg a Z0 0010 TLLLOSQV ajejd Buijunoj LiL 050 1055 14 eee ynokey 572 028 0701 KAESER COMPRESSORS Appendix 11 2 Spare Parts List 11 87 2195 9195 Jequunu OlquJe298J ep 582910 sej op 6 e uorioisod e o Ise anas e op op sou s oiquieoaJ sezaid uepid i NOIONALV eooid e 19 enb jreyedde 5 ON 9 19 e enbeuo ans Janbipu i NOILNALLV Jequunu wed DuuepJo JO pue aui Jequinu jenas pue Jequinu ped y ejonb 95604 i NOILNALLV OJ9polN ue 212529 Gunuuoiezeg pun Jeu unusuornisog 5 ed L Jap pun engen 91594 eis 9096 einig i 1 ap 089 4 2
46. the room to be heated The choice of exhaust air ducting length of ducting and number of bends can affect the compressor cooling system and must be approved by the manufacturer Reliable safe operation of the compressor package is only warranted if the temperature limits see chapter 1 6 of the air in the compressor space are kept to Further information on the discharge air ducts can be found in chapter 1 10 In confined places the minimum distance between one side of the compressor package and any wall can be reduced It is imperative that the minimum distance shown in the drawing is kept to to allow servicing work to be carried out without hindrance SS 1000 Air Connection The compressor package is piped ready for operation Before initial start it must be con nected to the air main with a flexible hose or axial compensator Measurements in mm Electrical Connection N The connection to the main power supply and the protective measures required are to be carried out by an authorized electrician to the re quirements of European Standard EN 1012 1 and EN 60204 1 and to the regulations of the local electricity authority The compressor package is wired ready for connection to the main power supply as de tailed in the electrical diagram The user of a compressor is obliged to carry out the following measures Compressor packages fitted with a drive motor greater than 3 kW and
47. valve 7 immediately Close the shut off valve 11 rz Remove the nipple with attached hose from the hose coupling 12 on the oil separator tank 5 Draining the oil on the oil cooler rz Place the oil container under the oil cooler rz Insert the nipple with attached hose 6 ball valve closed in the hose coupling 5b chapter 9 5 on the oil cooler rz Hang the attached hose into the container and secure Open the shut off valve 4 see chapter 9 5 rz Slowly open the ball valve 7 the remaining pressure in the oil separator tank es capes rz Close the shut off valve 4 see chapter 9 5 rz Remove the nipple with attached hose from the hose coupling 5 chapter 9 5 on the oil cooler Dispose of the used oil according to environmental regulations rz Open the ball valve 1 Adding oil N Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized rz Venting the compressor package see chapter 9 10 rz Unscrew the oil filler plug 4 on the oil separator tank Always use the same brand and type of oil when topping up the oil see label on the oil separator tank If a different type of oil is used drain the old oil completely and always renew the oil filter Never mix different types of oil rz up the oil to the maximum mark For oil quantity see chapter 1 7 rz Check the s
48. 1000050 bunvapuy 1 050 405584 sse Um 35 JV ______ 1 500113011 10 1 31013114 4851 UO 85 5 ay SO uoij3ajoJd JOJow 40558 44 0 7 3815 01 VOI uoMejoJ 10 38 0 uojjnqusnd 4015 001 s4ndul pueoq EOY 20 7 E 2 1 7 5 9 NE 9110 4 s LOXZ LOXZ 6110 6 2110 6 L LOXZ 9 LX 7 Sv LXZ v LXC EY LX ev LXE Y LXZ 7 61 97 4 19 2 l LEXC 9 EXC IY 3E0XC Y amp OXZ tY 2 0 4 EY OLOXZ 279 0 0 91 0XC 910X 2 910X 9 9 Ed yX 20 HL X eq 60 Jeqgz dy eq 96 e 141 44 14 1 ftpu 99 8 48 7 12 ES TIEOXZ EEOXZ te CEOXC 0XZ EXC LEXE IEXC EXC 32 9t om 20100 050 Bunudsun 246844 awen Bunsapuy 44819 20 00 0 TL ZLOSCS sndu p Jeoq wang LAL 050 1055844 38055 8040 Bunuapuy
49. 4 4 00012 182 192 050 Jim Bunoo S W 9 xoJddp y u 000 LOZ LLL OSO s u 92 xoJddo uu 0006 191 050 SOU 48 1 NOULIM SM 9 08 15401 dY 8 050 SOU NOULIM SM SL Dd OSL 10101 dv sz 050 SDU 4841 SM WW Si Dd OSL 10404 dv LOZ LLL OSO SJOU 48 1 SM 0 Dd 00 10404 050 Bul 3np ul 5501 8 0559 0 08111490 10480 541014 0 O 0 2 oc uapJa 14314 25 aJasun pasaga 550 pun uinjuabr3 sasun 151 Dunupia7 85911 JJapugab Jag anu 140 Gunuysiaz uajjouaqJoA UabunJapuy ajBuipagsBunppiu3 KAESER COMPRESSORS Safety Regulations 2 1 Safety Read this service manual carefully and observe cautionary references before putting this compressor package into operation and before carrying out any maintenance Explanation of Symbols and References AN cH This symbol is placed before all references to safety where danger to life and limb can occur It is especially important that these regulations are observed and that extreme care is taken For their own protection all other users must be informed of these safety regulations Observe general safety and accident prevention regulations as well as the safety regulat
50. Air cooler 2 cooler 3 Air cooler hose coupling 4 Shut off valve 5 cooler hose coupling 6 Cover plate rz Remove the cover plate 6 N Never direct compressed air at persons It is contained energy and as such is dangerous to life Always wear eye protection when blowing out the coolers t Blow out the cooler from inside to outside and vacuum the dust rz Replace the cover plate 6 If the coolers are badly clogged they should be cleaned by an author ized KAESER Service agency rz Close all access doors and fit all cover panels 9 6 KAESER COMPRESSORS Maintenance Cleaning or Renewing the Air Filter Clean the air filter when the corresponding service message on the SIGMA CONTROL is displayed see chapter 8 1 Change the air filter cartridge after two years use at the latest rz Stop the compressor package see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run 1 Snap fastener for opening the air filter housing 2 Air filter 3 Dusicap 4 Ar filter cartridge rz Open the access doors 1 and 2 see chapter 9 2 To open the air filter housing rz Open the snap fasteners 1 on the dust cap 3 and remove the dust 3 with the insert rz the insert out of the dust cap 3 rz Pullout the air filter cartridge 4 by turning lightly rz Clean the air filter housing dust cap insert and sealing surfaces Cleaning the air
51. EZ LON TS TX bad VAOL 745 60 LLX bos 201 _ AOE 0 VA0SZ my CX R lad 11 L HX 20 7 ALOH rs 4015 AINIDYAWI 29 4 9 7 lt lt gt gt t M ES ves 9 e 20 00 614 817 H 81 20101050 wasal Snapa 720 lt 0010 11410150 lt Ajddns LN 8 LII 080 4055844 ________ d wesbep ddS dV 15 2 Jajdepy JajsueJ Jaydepy 04440 suoipun 31013114 GLXZ 6 97 4 sal 9 SIN 610 2 SIS 610 T 9LO0XZ al 9 0 l 6 82 LON LON W EX 20 X WEN qns q 100 6 qns q 104 6 6X 90 2 0754 gy 587 54 JooJd 4045 ZL OLY 3 eubis 0 Oo 2 1 6L 0X 610 9L 0X 2 910 6 2 6 9 2 9X PLX v 17 20 9 JU vit 97 L 9 1 30 AvZ 101 W 20 18 20100 050 _ 20 6001 0 11410505 aJnjeaduia aueN Bunzspuy 0 4 d N3JOSS33dl40M
52. Ensure that the compressor package is level The floor must be solid with good loading characteristics See chapter 1 1 for the weight of the compressor package Safe operation of the compressor package is only ensured if the ambient temperature re mains within the limits stated in chapter 1 6 If the compressor package is used in the open take care that it is protected against the direct rays of the sun and against the ingress of dust and rain Install the compressor package as detailed in the following diagram Keep to the minimum distances shown to allow free access to the compressor package Adequate ventilation of the compressor space is ensured only if the minimum values see chapter 1 6 are adhered to VB h 22 Exhaust duct 14 22 M 7 2 fan a 2 cn CLA c 8 Me 2 Air inlet opening lt S A Exhaust duct 2 2 Air inlet b opening 7 Eos 22 2500 Measurements Solution A forced ventilation The exhaust fan fitted in the compressor space must provide adequate ventilation relative to the size of the compressor package see chapter 1 6 6 21 Installation 6 2 6 3 Solution B exhaust air used for space heating The hot air is forced through a duct into
53. Inlet valve Running the compressor package in idle At initial start run the compressor package in idle for 20 seconds by pressing the load idle key 5 see chapter 8 3 1 This measure ensures that the compressor package has sufficient time to flood the oil cir culation 7 29 8 8 1 8 2 8 3 KAESER COMPRESSORS Operation Operation Control Panel HAVES ER 1 SIGMA CONTROL 2 EMERGENCY STOP pushbutton SIGMA controller The SIGMA controller 1 is fitted in the control cabinet in the compressor package and serves as the control panel It has 11 keys and 9 LEDs Operation of the compressor pack age is determined by the settings programmed into the controller Further details on individual function keys LEDs and plain text display relating to possible alarms and service messages display of events etc are given in the service manual sup plied for the SIGMA CONTROL controller Emergency Stop Pushbutton The Emergency Stop pushbutton shuts down the compressor package immediately If the Emergency Stop pushbutton is pressed because of an existing hazard then this must be eliminated before the compressor package is reset accomplish this the follow ing procedure must be carried out rz Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows rz Acknowledge the alarm message on the controller by pressing the acknowledge reset key function keys see chapter 8 3 1 8
54. L 9L XZ 8E XZ El 0 4 3 50 6 Ajddns 0 410 i pueog Jayjou Jasn ayy uo gt Bis 431 aq __ ______ ___ lt _____ ___ gt _____ ___ _____ gt _____ ___ _____ ____ lt ____ __ ___ 201001050 1805 5 8040 435 3V C 6 Held 0 4 sjndjng p Jeoq LiL 050 JossaJduo JIn24rj c0 0010 10505 33JJ 1 0A 54 26 03 5 185 6 esp seen 9 eas Porat 18 LP 500113011 10 1 31013114 LY 77 ET EY ET 26 11 zE uo uv uu Lg 3 Ls 1M s M 5 t pag TV yop yop E 61 1 201 z 1 2001 LON El El JO 72 2 ANS xeu m 2 T T 6 9 9 6 z T ol 6 8 9 S 7 LY 20 O z n 0 5 COX 60 0 00 0 0 NO 10414101 0 0 40 103 ej a 200 10 3 103 200 JOJIEJUOD SUIP 00 0 Jasn uo 2 aq
55. SERVICE MANUAL Screw Compressor Model DSD 171 5 5 8 5 bar GL Nr 1 8701 2 00 02 Part No Serial No Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com KAESER Chapter Page 1 Technical Specification eee erect 1 1 1 1 Compressor Package 1 1 1 2 Sound Pressure Rep ERES Re 1 1 1 3 WIOLONE 0 0 00 1 1 1 4 1 2 1 5 Pressure Relief Valve 1 2 1 6 Installation Requirements 1 2 1 7 gt 1 2 1 8 Recommended Cooling Fluid 1 3 1 8 1 1 3 1 9 2 KAESERCOOMINO 215 vu ged eee 1 3 1 8 8 1 3 194 SIGMA FLUID PLUS dw 1 4 1 9 5 SIGMA 1 4 1 8 6 Compatibility of KAESER cooling fluid 1 5 1 9 Drive Motor Service Interval
56. able parts N The removal of faults that are not explicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agent see chapter 9 1 KAESER KOMPRESSOREN GmbH Carl Kaeser Str 26 96450 Coburg KOMPRESSOREN GERMANY Telefon 49 95 61 64 00 Fax 49 95 61 01 30 Serial No Year of production Rated power Rated motor speed Max working pressure g Ambient temperature Important for all queries rz Enter the data on your compressor s nameplate in the nameplate shown above Always quote the data on the nameplate when making a query or ordering spares Always order original spares from the compressor manufacturer to avoid lowering the quality of your compressor package Supplementary information for specialised personnel concerning spare parts is found in chapter 11 2 Oil filter 1200 Air filter cartridge 1250 Oil separator cartridge Complete set comprising 1450 Separator cartridge Gasket Dirt trap strainer O Ring Service and Maintenance Agreement We recommend that you take out a service and maintenance agreement with an author ized KAESER service agency This is your best guarantee of reliable air supplies 10 59 KAESER COMPRESSORS Appendix 11 Appendix 11 1 Electrical Diagram 11 60 20 50010 1141500 0 440 eufic 21000504 mnep sey 11218 LEL asa Jossasdwo N3JOSS33dl40M
57. arefully checked before shipment The test run confirms that the compressor conforms to specifications and runs perfectly However independent of the checks made at the factory the compressor could be dam aged during transport For this reason we recommend that the compressor package is examined for such possible damage Observe the compressor package carefully during the first hours of operation for any possible malfunction Important functional components in the compressor package such as minimum pressure check valve pressure relief valve inlet valve and combination valve are adjusted and fitted in the factory to precise set ting up regulations Alterations to these components are not allowed without previous consultation with the manufacturer N The minimum pressure check valve pressure relief valve and inlet valve are spring biased There is considerable danger of injury through the release of the spring when these components are opened Observe the following before starting N OF THESE OR OTHER INSTRUCTIONS WARN ING ATTENTION CAN LEAD TO ACCIDENTS CAUSING INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT The compressor starts automatically again when power returns after a power failure standard setting This is conditional on system pressure being lower than the pressure setpoint cut out pressure on SIGMA CONTROL Operation of the compressor with inspection doors open or cover pan el
58. at any time As it represents contained energy it is dangerous to life Inlet air may not contain any explosive or chemically unstable gas or vapour Compressed Air Treatment N Never use compressed air from oil injected compressor packages for breathing purposes and production methods where the air has direct contact with food without subjecting the compressed air to additional treatment Copyright All rights reserved No part of this publication may be reproduced or utilized in any form or by any means electronic or mechanical including photocopying and microfilm without prior permission in writing from KAESER COMPRESSORS Accompanying Documents With this Service Manual are documents intended to assist in safe and sure operation of the compressor e Certificate of acceptance operating instructions for the pressure vessel e Conformity or Manufacturer s Declaration in accordance with applicable directives e Service Manual and Declaration of Conforminty for pressure components see com pressor Declaration of Conformity rz Make sure all documents to hand and their contents understood Request the supply of any missing documents from KAESER Make sure you give the data from the nameplate 3 12 KAESER COMPRESSORS Transport 4 Transport 4 1 Transport Instructions We recommend a fork lift truck or lifting equipment for transporting the compressor pack age to avoid damage to the cabinet and fram
59. compressor operation Cooling fluids have vital tasks to fulfil e they function as a sealant in the airend to ensure maximum efficiency during the pro cess of compression they remove the heat caused by compression This cools the airend and reduces the temperature of the compressed air Cooling fluid must withstand heat and pressure and absorb the contaminations en countered in every compressor General information KAESER cooling fluid intended for fluid injected airends must be stored according to environ mental regulations and protected such that contamination and hazards are prevented It is imperative that national legislation covering transport storage use especially regulations for oil changes and disposal is observed The user accepts overall responsibility for safe and secure handling as soon as the cooling fluid enters his or her area of responsibility oafety data sheets for the cooling fluids mentioned are available from KAESER KAESER cooling fluid Several types of cooling fluid specially developed for use in KAESER s rotary screw com pressors are available Characteristics such as absorption of water lubrication and resis tance to aging are excellent Under conditions of very high ambient temperature or contamination the cooling fluid should be changed more frequently It is imperative that national oil change regulations must be observed The fluid separator tank is labelled with the type of c
60. d and idle 8 36 8 7 5 Pressure relief valve blowing off 8 36 8 7 6 EO ee ae Y rac 8 36 Ole 9 7 7 Cooling fluid consumption too high 8 36 8 7 8 9 Maintenance 9 38 9 1 Observe the following during all maintenance and servicing 9 38 9 2 Location of Access Doors and Cover Panels 9 39 9 3 Regular Maintenance 223 2 00 9 40 9 4 Oil teak Collector Bole 12 0 2 2x 19 di els E 9 41 9 5 Cleaning the Oil Cooler Air Cooler 9 42 9 6 Cleaning or Renewing the Air Filter 9 43 9 7 Servicing the Electric Motor 9 44 9 8 SOU IGS arr 9 44 9 9 Checking the Pressure Relief Valve on the Oil Separator Tank 9 45 KAESER Chapter Page 9 10 Venting the Compressor Package 9 45 9 11 OWN Garde scd quies Ea E eR Pee ERE P REESE sns 9 47 9 11 1 Removal and replacement of the oil filter 9 47 9 12 PPNO UP INE cooling MUNG aco us SO R
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62. e IRR Bos es 9 49 9 13 Oil Change Oil Separator and Oil Cooler 9 51 9 13 1 Draining the oil using external pressure source 9 52 DAG 2 Addng 01 um E este hee dm 9 53 9 13 3 Draining the oil using own compressed 9 53 9 13 4 Measures for putting back into operation 9 54 9 14 Changing the Oil Separator Cartridge 9 54 9 15 Assembly of the Flexible Pipe Connections 9 57 9 16 Flexible Pipe Connection Measurements 9 57 9 17 Record of Maintenance Work 9 58 10 Spare Parts and After Sales Service 10 59 10 4 Service parts and expendable 10 59 10 2 Service and Maintenance Agreement 10 59 1 1 a RD weds 11 60 1121 fs doas 11 60 112 Sere oia d e bee 11 87 KAESER COMPRESSORS 1 1 1 1 2 1 3 Technical Specification Compressor Package oats asic PPP DSD 171 Permissible gauge working pressure
63. e in the oil separator tank es capes rz Remove the nipple with attached hose 6 from the hose coupling 3 on the oil sepa rator tank Venting the air cooler Insert the nipple with attached hose 6 ball valve closed in the hose cou pling 8 chapter 9 5 on the air cooler Slowly open the ball valve 7 the air cooler and pipework up to the minimum pressure check valve are depressurized KAESER COMPRESSORS Maintenance rz Remove the nipple with attached hose 6 from the hose coupling on the air cooler N Close all access doors and panels correctly before starting the com pressor package 9 11 Oil Filter Change N Hot oil beware of scalding 1 Screw plug A special oil filter is fitted to clean the oil system during the running in period during which time the main oil bore in the combination valve is closed with a screw plug Replace the special oil filter with a standard oil filter after approxi mately 200 service hours Ensure that the screw plug is removed from the main oil bore in the combination valve A further filter change is recommended after the interval quoted in the regular maintenance table see chapter 9 3 or when the corresponding service message is displayed on SIGMA CONTROL see chapter 8 1 The filter must be changed after every oil change 9 11 1 Removal and replacement of the oil filter rz Shut down the compressor package under full load see chapter 8 4 N Switc
64. e procedures Venting the Compressor Package chapter 9 10 and Topping up the Oil chapter 9 12 Maintenance KAESER COMPRESSORS Always use the same brand and type of oil when topping up see label on the oil separator tank If the type of oil is changed drain the old oil completely and renew the oil filter Never use different types of oil 9 13 Change Oil Separator and Oil Cooler Carry out the oil change with the compressor at operating temperature N Hot oil beware of scalding The oil change interval is dependent on the degree of cooling air contamination and on the ambient temperature If the compressor package is operated close to the maximum permissible ambient tem perature see chapter 1 6 the oil must be changed more often if necessary the interval should be halved See regular maintenance table chapter 9 3 for oil change interval Drain the oil out of the separator tank cooler and the pipework com pletely See chapter 9 13 4 for putting back into operation rz Shutdown the compressor package under full load see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run N Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized rz Venting the compressor package see chapter 9 10 KAESER COMPRESSORS Maintenance
65. e shut off valve 20 see chapter 5 3 must be open Carry out the following work only when power is removed from the compressor package Check all screws on the electrical connections for tightness carry out this check again after 50 operating hours e This compressor package is fitted with a running in oil filter Replace the filter after the running in period of 200 hours has elapsed see chapter 9 11 7 25 KAESER COMPRESSORS Initial Start 7 3 Checklist rz Is the floor at the place of installation solid and level yes rz Is the space large enough for the compressor package or its components yes no rz inlet and exhaust apertures available in sufficient size and number yes no rz components of the compressor package easily accessible yes rz Is the power supply cable of sufficient cross section have electrical connection carried out by qualified electrician or company familiar with local conditions yes rz lIsashut off valve fitted by the user yes Isa flexible connecting hose or compensator fitted between the compressor package and the air main yes no rz Have all screws bolts and electrical connections been checked for tightness yes Has the oil level in the oil separator been checked yes no Is amain switch fitted sui
66. ealing ring on the oil filler plug 4 for damage and then screw in the oil filler plug rz Close all access doors and fit all cover panels Draining the oil using own compressed air rz Shutdown the compressor package under full load see chapter 8 4 9 13 4 9 14 KAESER COMPRESSORS Maintenance N Switch off and lock out the main switch to prevent an accidental com pressor run rz Close the shut off valve between the compressor package and the air main The compressor oil circulation vents automatically rz Remove cover panel 5 see chapter 9 2 rz pressure gauge on the oil separator tank must indicate zero bar rz Close the shut off valve 1 rz Close all access doors and fit all cover panels rz Start the compressor package see chapter 8 4 and allow to run for approximately 30 seconds rz Shutdown the compressor package under full load see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run Remove cover panels 5 and 6 see chapter 9 2 Check the actual pressure on the pressure gauge 2 Open the shut off valve 1 let the pressure on the pressure gauge 2 sink to approximately 3 bar and then close the shut off valve 1 again rz Drain the oil from the oil separator tank and the oil cooler Proceed as detailed in chap ter 9 13 1 rz Open the shut off valve 1 up with oil as described in chapter 9 13 2 rz Close all acc
67. ed filter and used oil carefully according to environ mental regulations rz Clean the sealing faces carefully with lint free cloth rz Lightly oil the gasket of the new oil filler before screwing into position rz Spin on the new oil filter clockwise by hand until the gasket fits tightly Do not use a tool as this may cause damage to the oil filter and the gasket 9 12 KAESER COMPRESSORS Maintenance rz Check the oil level see chapter 9 12 rz Close all access doors and fit all cover panels rz Open the shut off valve between the compressor package and the main N Carry out a trial run When the operating temperature is reached see chapter 1 1 shut down the compressor package see chapter 8 4 and lock out the main switch to prevent an accidental compressor run Carry out a visual check for leaks Topping up the cooling fluid The fluid level shown by the indicator 9 should be checked weekly with the machine at operating temperature and under load The machine should be topped up with cooling fluid as soon as the minimum fluid level 1 border of green and red is reached For the quantity of fluid needed to top up to maximum fluid level 3 see chapter 1 7 The machine may only be operated when the fluid level indicator is in the green zone A Q 22 1 Lowest oil level 2 Optimum oil level 3 Highest oil level rz Check the oil level when the machine is under full load and at operati
68. ed personnel under the supervision of a trained electrician according to electrical engineering regulations The compressor starts automatically again when power returns after a power failure standard setting This is conditional on system pressure being lower than the pressure setpoint cut out pressure on SIGMA CONTROL Switch off and lock out the main switch before attempting any mainten ance work see chapter 2 3 Ensure that no maintenance personnel are working on the vacuum package that all panels are screwed back on again and that all access doors are closed before restarting See chapter 8 4 to restart the vacuum package The following points must be observed when handling lubricating and cooling materials Avoid contact with skin and eyes Do not inhale vapours and oil mist Do not eat or drink when handling such materials Fire open flame and smoking are strictly forbidden Ensure that all lubricants consumable materials and replacement parts accumulating during operation and servicing of the compressor package are disposed of according to environmental regulations The plug in nipple with ball valve and attached hose required to vent the oil separator tank for maintenance work such as topping up the oil oil changes and filter changes is located under the oil separator tank If the compressor package is installed directly in front of a wall then the accessibility of components may be limited If necessary r
69. emove further panels 9 38 66 6 12 11 9 1 2 Access doors 3 4 Control cabinet doors 5 11 Cover panels 12 13 Upright panels 6 6 19A02 pue 51004 55922 Jo 207 4 5 0 v 2 m o 2 o KAESER RS COMPRESSO 9 3 Maintenance Regular Maintenance 50 hours after initial Check all electrical terminals and tighten if start up necessary 200 hours after initial Change fluid filter 9 start up weekly Check fluid level Check fluid leak bottle Indicated by Clean or change air filter SIGMA CONTROL Change fluid filter Changing the fluid separator element 1000 h Check fluid air cooler for clogging 2000 h or at least an Grease the motor bearings nually 3000 h Check the coupling up to 3000 h yearly at Change fluid filter the latest Variable Change the cooling fluid see chapter 1 8 annually Check all electrical terminals and tig
70. ess doors and fit all cover panels Measures for putting back into operation rz out measures detailed in Pouring a small quantity of oil into the air inlet port see chapter 7 8 1 rz Carry out measures detailed in Running the compressor package in idle see chapter 7 8 2 rz Carry out the measures detailed in Venting the compressor package see chapter 9 10 Top up with oil see chapter 9 13 2 Open the shut off valve between the compressor package and the air main owitch on the compressor package see chapter 8 4 and allow to run until the operat ing temperature is reached see chapter 1 1 Top up the oil again see chapter 9 12 N Carry out a trial run When the operating temperature is reached see chapter 1 1 shut down the compressor package see chapter 8 4 and lock out the main switch to prevent an accidental compressor run Carry out a visual check for leaks Changing the Oil Separator Cartridge The service life of the oil separator cartridge is strongly influenced by the degree of conta mination of inlet air and on strict adherence to the recommended maintenance intervals of the air and oil filters We recommend that the oil separator cartridge is changed with the oil or when the relevant service message alarm message 15 displayed on SIGMA CONTROL see chapter 8 1 KAESER COMPRESSORS Maintenance rz Shut down the compressor package under full load see chapter
71. ework O min 1900 Measurements in mm Do not exert any side forces on the compressor package when trans porting with lifting equipment 4 2 Packaging Always observe the instructions in chapter 4 3 when packaging the machine for storage Use packaging suitable for the intended route if the machine is to be transported further by the customer Overland The machine should be protected from mechanical damage by a sturdy crate and from moisture by plastic sheeting By sea or air opecial packaging instructions can be obtained from KAESER Dispose of the packaging according to environmental regulations and recycle where possible 4 13 4 3 KAESER COMPRESSORS Transport Storage If the equipment is to stand idle for a long period the prescribed measures must be taken to avoid damage If any measures can not be taken advice should be sought from the authorised KAESER Service depot Basically the equipment should be stored in a dry frost free room Protect against ingress of moisture or formation of condensation See chapter 7 8 for instructions on start up Storage up to 6 months temporarily out of service As an alternative to storage the equipment can be run once a week for 30 minutes at op erating temperature to ensure adequate corrosion protection Otherwise the measures described under Storage for longer than 6 months are to be taken Storage for longer than 6 months
72. filter cartridge 4 by tapping rz the air filter cartridge several times on the front with the ball of the hand Do not use force otherwise the air filter cartridge may be damaged rz Clean all sealing surfaces Cleaning the air filter cartridge with compressed air rz Blow dry compressed air at a pressure of not more than 5 bar at a slant from the in side to the outside of the air filter cartridge surfaces Do not clean the air filter cartridge with fluids If the air filter cartridge is heavily contaminated or was already cleaned several times max five times renew To close the air filter housing rz Insert the air filter cartridge 4 Note the insertion mark on the dust cap rz Guide the insert into the dust cap 3 rz Replace the dust cap 3 and close the snap fasteners 1 rz Close all access doors and fit all cover panels 9 7 9 8 KAESER COMPRESSORS Maintenance Servicing the Electric Motor Drive motor The bearings can be greased using the external grease nipples See chapter 1 9 for greasing periods quantity and approved greases Grease the bearings at the correct interval chapter 1 9 from the external grease nipples while the motor is running The grease pipes from the bearings to the nipples are full on delivery See chapter 1 10 for the location of the grease nipples Motors manufactured to IP 55 protection have no outlet bores for the grease The motor bearings must be renewed
73. final pressure of the compressor package must be increased above the pressure parameter entered in the controller See chapter 1 5 for the operating pressure of the pressure relief valve The pressure relief valve must be checked by an authorized KAESER service agency when the interval quoted in the regular maintenance table see chapter 9 3 has expired Detailed information is to be found in the service manual for SIGMA CONTROL Venting the Compressor Package rz Shutdown the compressor package see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run rz Close the shut off valve between the compressor package and the air main The oil circulation vents automatically KAESER COMPRESSORS Maintenance Venting the oil separator tank 1 Shutoff valve 4 Threaded plug 8 Maintenance hose A closed topping off oil 9 Oll level indicator B open 5 separtor tank 11 Oil drain shutoff valve 2 Pressure gauge 6 Plug in nozzle 12 Hose coupling 3 Hose coupling Ball valve rz Remove cover panels 5 and 9 see chapter 9 2 rz The pressure gauge on the oil separator tank must indicate zero bar N Oil mist can escape when the oil separator tank is vented rz Insert the nipple with attached hose 6 ball valve closed in the hose cou pling 3 on the oil separator tank rz Slowly open the ball valve 7 and the remaining pressur
74. h off and lock out the main switch to prevent an accidental com pressor run N Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized rz Venting the compressor package see chapter 9 10 rz Remove cover panel 6 see chapter 9 2 If because of lack of space the oil filter is not accessible then remove the corner post 1 and the oil filter together with its components Re assemble in the reverse order correspondingly KAESER COMPRESSORS Maintenance we iE Ju 2182 2 AI 42 28 amp _ 2 2 5 as P 6354565 Eee 2 Em SSIs N 2 q 3262 EM 1 Corner post 2 screw 3 Screw 4 Flexible pipe connection 5 Bolt 6 Combination valve rz Remove the corner post 1 by unscrewing the screws 2 rz Unscrew the screw 3 and pull out the plug rz Open the flexible pipe connection 4 Oil can leak out of the openings rz Remove the bolts 5 on the combination valve 6 rz Take out the combination valve 6 and hold with a suitable jig 1 filter cartridge 2 in this direction to unscrew the cartridge rz Spin off the used or contaminated oil filter counter clockwise and catch escaping oil in a suitable container D Dispose of the us
75. hten if necessary Check the pressure relief valve 12000 h Have the valves inspected by an authorized KAESER service agency up to 20000 36000 h Change the drive motor bearings at the latest every 8 years The maintenance interval may change according to the motor starting frequency and ambient conditions We strongly recommend keeping a maintenance record see chapter 9 17 and to have the compressor package particularly the safety devices checked annually by an authorised KAESER service agent KAESER COMPRESSORS Maintenance 9 4 Oil Leak Collector Bottle On airends with a sliding ring seal a small amount of oil may penetrate through this type of seal This small leakage is directed into an oil leak collector bottle located underneath the air end Check the oil level in the oil leak collector bottle weekly Contact KAESER COMPRESSORS if leakage becomes excessive 1 Oil leak collector bottle 9 5 KAESER COMPRESSORS Maintenance Cleaning the Oil Cooler and Air Cooler The oil cooler and air cooler must be checked for clogging regularly Heavy clogging may cause high temperatures in the oil circulation See regular maintenance table for cooler service interval chapter 9 3 rz Switch off the compressor unit under full load see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor start rz Remove cover panel 6 see chapter 9 2 1
76. ime the time during which the air main pressure rises from the lower to the upper switching point baecay pressure decay time the time during which the air main pressure decays from the upper to the lower switching point Functional description Two fixed periods the running period and idle standstill period are taken as the crit erium for selection of the operating mode of the compressor package when the air main pressure reaches the upper switching point These two periods are set according to the maximum permissible starting frequency of the drive motor The running period starts every time the compressor package is switched on It lasts as long as the drive motor runs and stops when the compressor package switches to stand still The idle standstill period starts every time the operating mode changes from full load to idle It runs during idle and also when the compressor package is switched to standstill after the idle period It stops when the compressor package switches to full load Every switching off point is delayed by the run on period during which time the com pressor package vents The following switching cycles are possible e Ifthe air main pressure decays to the lower switching point the compressor package switches to full load 1 irrespective of its previous operating mode If the drive motor was at a standstill the opening of the inlet valve is delayed to allow an unloaded com pressor package start 5
77. ions laid down in this service manual This symbol is placed by text where considerable attention must be paid so that recommendations regulations references and correct se quence of work are adhered to and that damage and or destruction of the compressor package and or other equipment is prevented This symbol identifies environmental protection measures This symbol indicates operations to be carried out by the user This bullet identifies listings Explanation of warning labels gt gt E Beware of hot surface Do not touch surface danger of burning Beware of high voltage Do not touch electrical components danger of electric shock Beware Machine starts automatically Machine can start automatically or by remote start command Beware of rotating parts Do not touch rotating parts as this can cause pinching injury KAESER COMPRESSORS 2 2 Safety General Safety Instructions gt gt 1117 Work on power driven systems may only be carried out by trained instructed personnel or by specialised personnel Work on electrical equipment in the compressor package may only be carried out by a trained electrician or trained personnel under the supervision of a trained electrician according to electrical engineering regulations Before work is carried out on electrical systems carry out the follow ing measures in the sequence shown Switch off all phases Ensure the unit cannot be swi
78. k and clean the dirt trap strainer in the fluid scavenge line Check valve spring and activating pis ton Replace defective parts Drain off old cooling fluid and replace with recommended type Ask an authorized KAESER service agent for recommendations on cooling fluid types Change the fluid filter see chapter 9 11 Have the airend checked by an autho rised KAESER service agent Remedy Check the wiring and reset the relay if necessary Replace a defective overload relay Check power supply and wiring Change fuse s or motor as necessary 8 34 KAESER COMPRESSORS Possible cause 8 7 3 8 7 4 Oil separator cartridge clogged Motor starts against pressure as the compressor has not vented Airend defective Ambient temperature too high Motor defective bearing damage or winding short Compressor runs but does not reach pressure Possible cause Motor turning in the wrong direction Inlet valve not opening or only opening partially Venting valve not closing under full load Minimum pressure check valve defec tive Leaks In the machine Leaks in the air supply system The air demand 15 greater than the ca pacity of the compressor The maintenance hose coupling 15 still plugged into the oil separator or after cooler Pressure relief valve blowing off Oil running out of air filter Possible cause Oil level in the separator tank too high Defective inle
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80. ng temperature rz Shut down the compressor package under full load see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run rz Remove cover panel 5 see chapter 9 2 N Before opening or removing pressurized components pipes hoses tanks etc it is imperative that the compressor package is completely depressurized rz Venting the compressor package see chapter 9 10 KAESER COMPRESSORS Maintenance 1 Shutoff valve 4 Threaded plug 8 Maintenance hose A closed topping off oil 9 Oll level indicator B open 5 separtor tank 11 Oil drain shutoff valve 2 Pressure gauge 6 Plug in nozzle 12 Hose coupling 3 Hose coupling Ball valve rz Unscrew the oil filler plug 4 on the oil separator tank Fill with oil up to the maximum indicator level See chapter 1 7 for the oil volume needed to increase the indicated level from minimum to maximum rz Check the sealing ring of the filler plug 4 for damage and then replace the filler plug rz Close all access doors and fit all cover panels rz Open the shut off valve between the compressor package and the air main After carrying out the oil change or oil cooler cleaning with removal of the oil cooler run the compressor package up to operating tempera ture to ensure that the combination valve closes and that the oil cooler is flooded with oil Afterwards repeat th
81. nt oee motor nameplate for the rated motor current Value To prevent the overload circuit breaker from triggering because of voltage fluctuations temperature influences or component tolerances the set value can be up to 15 higher than the arithmetical phase current 1 Motor phase current adjustment 2 Reset button 7 27 7 6 7 7 KAESER COMPRESSORS Initial Start Setting the Motor Overload Protection Switch N Before any adjustments are carried out to the compressor package break the power supply by operating and locking out the main isolat ing device main switch to prevent an accidental compressor start See chapter 2 3 The standard setting is made at the factory Fan Motor direct on line start In direct on line start the starting current is fed via the motor overload protection switch oee the nameplate on the motor for rated motor current Setting This can be set to a maximum of 10 higher than the rated motor current to prevent trig gering of the motor overload protection switch under conditions of voltage fluctuation 1 Motor phase current 2 Adjusting lever Setting the Air Main Pressure Threshold The air main pressure threshold is preset at the factory It can be changed in SIGMA CONTROL to match customer s operational requirements if the password is known For further details consult the SIGMA CONTROL service manual Switching from full load to idle running may take place no m
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83. ooling fluid used Change intervals The duty cycle and ambient conditions are important criteria for the number and length of the change intervals Cooling fluid Description maximal permissible fluid change inter val in operating hours years favourable operat unfavourable oper ing conditions ating conditions SIGMA FLUID PLUS Synthetic oil 9 000 3 6 000 1 SIGMA FLUID FGL Synthetic oil 3 000 1 2 000 1 cool to moderate ambient temperatures low humidity high duty cycle 1 8 4 1 8 5 KAESER COMPRESSORS Technical Specification SIGMA FLUID PLUS SIGMA FLUID PLUS is the standard KAESER cooling fluid Based on synthetic poly alpha olefins it is characterised by its long life excellent lubrica tion and low evaporation loss It is recommended for ambient temperatures up to 45 KAESER SIGMA FLUID PLUS has the following properties e Viscosity at 40 C DIN 51562 1 70 mm s e Viscosity at 100 C DIN 51562 1 10 6 mm 2 s e Density at 15 C DIN 51757 843 kg m 6 Flash point DIN ISO 2592 260 C e Pour point DIN ISO 3016 39 C Water separability at 54 C DIN 51599 30 min Very good oxidation stability Good anti wear properties e Excellent dispersant and detergent properties e High viscosity index e Very good demulsifying properties 6 Low evaporation loss Cooling fluid part number SIGMA FLUID PLUS 4 Part No 9 1468 2 SIGMA FLUID PLUS 20 Part No 9 1459 2
84. ore fre quently than 2 times per minute Switching frequency can be improved by increasing the difference between cut in and Cut out pressure In addition a larger air receiver can be installed to increase buffer capacity 7 28 7 8 7 8 1 7 8 2 KAESER COMPRESSORS Initial Start Measures to be taken before Initial Start Take the following measures before initial start after an oil change or a shutdown period of three months or longer Pour a small quantity of oil into the air inlet port N Switch off and lock out the main switch N Do not add oil unless the compressor package is completely vented See chapter 9 10 to vent the compressor rz Unscrew the filler plug 1 on the inlet valve 2 and pour the prescribed quantity of oil see chapter 1 7 into the airend rz Turn the airend counterclockwise by hand using the coupling rz Screw the plug back in again This oil must be of the same type as used to run the compressor see label near the oil filler plug on the oil separator tank If no additional oil is available then remove the required amount of oil from the oil separator tank See chapter 9 13 for this procedure If the compressor package was shut down for longer than 12 months further measures must be taken before putting it back into operation Consult the manufacturer first rz Open the shut off valve between the compressor package and the air main 1 Filler plug 2
85. rator cartridge 23 together with the gaskets 21 and dispose according to environmental regulations rz Clean the sealing surfaces of the oil separator tank The oil separator cartridge cannot be cleaned rz Insert the new oil separator cartridge 23 with new gaskets 21 and fit and tighten down the cover 14 with the hex bolts 17 rz Renew the strainer and O ring in the dirt trap 15 when the oil separator car tridge 23 is renewed Reassemble in the reverse order For instructions on assembly of the flexible pipe connection see chapter 9 15 rz Close all access doors and fit all cover panels rz Open the shut off valve between the compressor package and the air main Carry out a trial run When the operating temperature is reached see chapter 1 1 shut down the compressor package see chapter 8 4 and lock out the main switch to prevent an accidental compressor run Carry out a visual check for leaks 9 15 9 16 KAESER COMPRESSORS Maintenance Assembly of the Flexible Pipe Connections rz Stop the compressor package see chapter 8 4 N Switch off and lock out the main switch to prevent an accidental com pressor run 5 6 p 5 a 1 Pipe 5
86. re that all lubricants consumable materials and replacement parts accumulating during operation and servicing of the compressor package are disposed of according to environmental regulations The following points must be observed when handling lubricating and cooling materials Avoid contact with skin and eyes Do not inhale vapours and oil mist Do not eat or drink when handling such materials Fire open flame and smoking are strictly forbidden 2 e 3 1 3 2 3 3 3 4 3 5 KAESER COMPRESSORS General General N The service manual must always be available for use at the location of the compressor package Correct use The compressor package is intended solely for the purpose of generating compressed air Any other use is considered incorrect The manufacturer cannot accept liability for any consequential damage caused by such incorrect use the user alone is liable for any risks incurred Correct use of the compressor also encompasses adherence to the installation disassem bly commissioning operational and maintenance conditions laid down by the manufac turer This compressor package may only be used for industrial purposes If the compressor package is operated in an air distribution network the maximum network pressure may not exceed 16 bar The equipment may only be used or serviced by persons who are au thorised and trained Incorrect Use N Never direct compressed air toward any person
87. ry Have the valve inspected by an autho rized KAESER Service Technician Compare the valve blow off pressure with the information on the compres sor nameplate If necessary have an authorized KAESER Service Technician replace the valve Remedy Remove hose coupling from the con nection point see chapter 8 7 5 see chapter 8 7 4 Tighten up hose coupling or replace as necessary Have the oil cooler replaced by an au thorized KAESER Service Technician Remedy Replace with recommended cooling fluid Refer to authorised KAESER service agent for advice on oil types 8 36 KAESER COMPRESSORS Possible cause Fluid separator cartridge split Fluid separator tank cover not securely fixed Fluid level in the separator tank too high Fluid scavenge line clogged Operation Remedy Check pressure drop across the sepa rator cartridge and replace if neces sary Tighten up fixing screws Drain off cooling fluid until the correct level is reached Check dirt trap strainer in the scav enge line Clean or replace as necessary 8 37 KAESER COMPRESSORS 9 Maintenance Maintenance 9 1 Observe the following during all maintenance and servicing A 117 Work on power driven systems may only be carried out by trained supervised or specialised personnel Work on electrical equipment in the compressor package may only be carried out by a trained electrician or train
88. s removed is strictly forbidden as injury can result from rotating parts or electrical components Remove all packing materials tools and transport devices on and in the machine It is expected that safe working methods are used and that all locally applicable oper ational and safety regulations are complied with The user is responsible for the safe operating condition of the compressor package Do not operate this compressor package in environments where the air is heavily con taminated with dust or where toxic or inflammable gases may be present Do not connect the compressor package to a power supply different to that shown on the nameplate Do not install the compressor package in an environment subject to freezing tempera tures The air temperature specified for the air intake must be kept to see chapter 1 6 If exhaust ducting is fitted it must have a cross sectional area at least equal to the cooling air outlet on the compressor package itself and may not create a pressure drop greater than that specified by the compressor manufacturer 24 KAESER COMPRESSORS Initial Start The compressor must be positioned with its cooling air inlet opening at least 1 m from any wall Check the cooling fluid level in the fluid separator tank see chapter 9 12 The airend shaft must rotate in the correct direction see chapter 7 4 The shut off valves 6 6 and 11 6 see chapter 5 3 must be closed Th
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90. t rating of 16 amperes or above must be fitted with with a lockable main switch see EN 60204 1 P 5 3 and mains fuses 6 The type of main switch used is dependent on the power consumption of the drive motor see chapter 1 4 for value e The type of protective circuit breaker used is dependent on the starting characteristic of the drive motor See chapter 1 4 for recommended cable cross sections and fuses Spare Parts Genuine KAESER parts are designed and matched to meet the technical requirements of the compressor package This means that safe and reliable operation of the compressor package can only be guar anteed if genuine KAESER spare parts and KAESER SIGMA FLUID is used Use only original parts in assemblies subject to pressure Compressed Air Installation If a compressed air installation is extended or changed check the blowoff pressure of the pressure relief valves on the air receiver tanks and in the pipework before the new com pressor package is installed If the blowoff pressure is too low fit a pressure relief valve with correspondingly higher blowoff pressure 2 10 KAESER COMPRESSORS 2 6 Environmental Protection Safety Condensate drainage 6 The condensate accumulating during compression must be fed via a suitable drainage system into special canisters and disposed of ac cording to environmental regulations Lubricants consumable materials replacement parts E Ensu
91. t valve Operation Remedy Check pressure drop over the oil sepa rator cartridge If necessary change oil separator cartridge and dirt trap sieve Check that the vent line ball valve is open Check the venting valve diaphragm and change if necessary Have the minimum pressure check valve inspected by an authorized KAESER Service Technician Have the airend inspected by an au thorized KAESER Service Technician Arrange a supply of cooler air or move the machine to a cooler place see chapter 1 6 Have the motor repaired or replaced by an authorized KAESER Service Centre Remedy Check motor connections Have the valve inspected by an autho rized KAESER Service Technician Check the combination control venting valve and lines and pipework Replace defective parts Have the valve inspected by an autho rized KAESER Service Technician Tighten all loose connections repair or replace defective parts Check for open valves loose connec tions defective parts or gaskets etc and seal or replace Reduce the air demand or install addi tional compressor capacity Remove hose coupling from the con nection point see chapter 8 7 5 Remedy Drain off oil till the correct level rea ched Have the valve inspected by an autho rized KAESER Service Technician 8 35 KAESER COMPRESSORS 8 7 5 8 7 6 8 7 7 8 7 8 Too frequent switching between load and idle Possible cause
92. tched on again Check that no voltage is present Unless the Service Manual states otherwise all pressure lines must be vented or shut off Any alterations or reconstruction carried out without consultation with and the previous consent of KAESER COMPRESSORS will invalidate the warranty No welding heat treatment or mechanical modifications may be car ried out on pressurised components such as pipework air receivers etc Safety devices may not be modified or deactivated Signs and marks of reference may not be removed or rendered unre adable The relevant statutory regulations must be observed during installation operation mainten ance and repair of the compressor package These are for example nationally applied European directives and or valid national laws safety and accident prevention regulations These instructions must also be observed Allow no open flames and flying sparks at the place of installation Ensure that sparks or high temperatures cannot cause fire or explosion if welding is carried out on or near the compressor Ensure that the compressor unit can breathe clean intake air that contains no damag ing components Do not allow the maximum ambient temperature to be exceeded see chapter 1 6 otherwise special measures must be agreed between the manufacturer and the cus tomer Carry out oil changes according to the service manual Use only oils recommended by the manufacturer
93. ted to the motor starting characteristics yes Has the setting of the drive motor overload current trip been checked yes no rz Have you ensured that there no other components located in the exhaust air flow of the compressor package yes rz Have service personnel been instructed on safety regulations yes 7 26 KAESER COMPRESSORS Initial Start Direction of Rotation Check The compressor package Is wired for connection to a clockwise phase sequence A check of the direction of rotation can be made by testing the phase sequence Arrows showing the direction of rotation are located on the motor and on the air end hous ing If the direction of rotation is incorrect change over the supply conductors L1 and L2 If the air end rotates in the wrong direction the compressor package is automatically shut down by the pressure switch 4 2 see chapter 5 3 Setting up the Motor Overload Trip N Disconnect the supply voltage to the compressor package by switch ing off and locking out the main switch before any adjustments are carried out on the compressor package See chapter 2 3 for the main switch The trip is set to the standard adjustment at the factory Compressor motor star delta start In the star delta configuration the phase current is fed via the motor overload trip This phase current is 0 58 times the rated motor curre
94. xplicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agency Working temperature too high Possible cause The distance from the cooling air inlet or outlet is too small Insufficient cooling air flow Ambient temperature too high If ducting is used for cooling air dis charge it could be too narrow or too long If the machine is air cooled the fluid air cooler could be clogged If the machine is water cooled the heat exchanger could be clogged by deposits Air inlet filler mats clogged Fluid level too low Thermostatic valve not functioning cor rectly Wrong cooling fluid used Fluid filter clogged Airend defective Motor overload protection relay trips Possible cause Protection relay is defective or incor rectly set Motor runs on two phases motor de fective or one of the customer s fuses blown Remedy Keep to the minimum distance and en sure sufficient ventilation Ensure sufficient ventilation Arrange for a supply of cooler air or move the machine to a cooler place see chapter 1 6 Have an authorised KAESER service agent install adequately sized ducting Clean the fluid air cooler see chapter 9 5 Have an authorised KAESER service agent inspect clean or replace the heat exchanger as necessary Clean or replace the filter mats Top up to the correct level with recom mended cooling fluid Chec

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