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KAESER SX6 Service Manual

1. Tab 20 Maintenance log 10 51 11 KAESER COMPRESSORS Spares Operating Materiels Service Spares Operating Materials Service Note the nameplate Take data from the nameplate for all inquiries and spare parts orders Ordering Maintenance Parts and Operating Materials AI Personal injury or machine damage may result from the use of unsuit able spare parts or operating materials CAUTION Unsuitable or poor quality maintenance parts and operating materials may damage the machine or impair its proper function Damage to the machine can also result in personal injury Use only genuine spare parts and authorized operating materials Have an authorized KAESER service agent carry out regular mainte nance KAESER maintenance parts and operating materials correspond to the original These are correct for use in our machines Compressor Name Quantity Number Air filter cartridge 1 1250 Filter mat 1 1050 filter 1 1200 separator cartridge 1 1450 Cooling Oil 1 1600 Drive belts set 1 1800 Tab 21 Machine maintenance parts Maintenance Contract Signamaintenance contract with an authorized KAESER distirbutor This ensures the utmost reliability and availability of your compressed air supply system Service Addresses Addresses of KAESER distributors are given at the end of this manual Spare Parts for Serv
2. 10 46 17 Cooler with fixings c a E dun 10 48 Fig 18 Gooler fixing Ned a 10 48 Fig 19 Changing the Separator Cartridge 10 50 Fig 20 Transport by fork truck 12 62 Fig 21 Transport with lifting cradle 12 63 KAESER COMPRESSORS Table Directory Chapter page Tab 1 Nameplate 1 eek eet ee pu bete durus kt 2 3 ees 2 3 Machine temperatures 1 2 3 Tab 4 Ambient Conditions 2 3 Tab 5 Pressure switch setting 1 2 4 Tab 6 Safety relief valve setting 2 4 7 Delivery o 2 4 Tab 8 Sound Pressure 2 4 Tab 9 Compressor motor data 2 5 Tab 10 Cooling 2 2 2 6 11 Electrical connections data 2 7 Tab 12 2
3. ee Beds 3 12 3 Ventilation hee eo ee eee 5 18 Tab 14 Overload protection relay settings 6 22 Tab 15 Installation conditions 7 24 16 Regular Maintenance Work 1 10 35 17 Oil change intervals 10 36 18 Oil change intervals speciality lubricants 10 36 Tab 19 Regular service work intervals 10 36 20 Maintenance log 10 51 Tab 21 Machine maintenance parts 11 52 1 1 1 2 1 3 1 4 1 4 1 KAESER Regarding this Document Handling the Document The service manual is part of the machine t Keep the service manual in a safe place throughout the life of the machine Pass the manual onto the next owner user of the machine Ensure that all amendments are entered in the manual d WW Enter details from the machine nameplate in the table in chapter 2 Technical Specifica tions Further Documents Included with this Service Manual are documents intended to assist in safe and sure opera tion of the machine e certificate of acceptance operati
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5. 10 36 10 2 3 Regular Service Work 10 36 10 3 Air Filter Maintenance 10 37 10 4 Filter Mat Maintenance 10 37 10 5 Electric Motor Maintenance 10 38 10 6 Checking the Safety Relief Valve on the Separator Tank 10 38 10 7 Maintain the Drive Belts 10 39 10 7 1 Check the belts and their tension 10 39 10 7 2 Changing the 10 40 10 8 Vent the Machine Manually 10 40 10 9 Checking and Topping Up the Cooling 1 10 41 10 9 1 Checking cooling 10 41 10 9 2 Topping up the cooling Oil 10 42 10 10 Changing the Cooling 10 44 10 11 Oil Filter Maintenance 10 46 10 12 Cooler Maintenance 10 47 10 13 Changing the Separator Cartridge 10 49 10 14 Logging Maintenance 1 1 4 10 51
6. um ux KAESER COMPRESSORS terminal connection compressor SX 6 condensate drain 1 Pal 3 3 t i o o gt 3 3 2 KSX6 WE U0019 01 Page ie KAESER lay out 5 6 U0019 01 B COMPRESSORS 5 6 ue Pae
7. Tm KAE SER terminal connection KSX6 U0016 01 69 Toate nme 79 KAESER 5 6 00016 01 check Gegner COMPRESSORS compressor SX 6 modification _ 1 Wiring Diagram screw compressor SX 6 direct on line start 230V 3 60 460V 32 60 manufacturer KAESER COMPRESSORS 96450 COBURG GERMANY consignee customer EN UM KAESER page DSX6 U0024 01 ee a compressor SX 6 Pa Input voltage 230V 93 60CY 460V 93 60 supply line cross section and fusing see service manual s b c supplied by customer hh 6 8 5A adjusted 7 5 20L 6 8 5A adjusted 7 5A 0 5A 2FU 0 5A ATTENTION If the power supply voltage is changed the jumpers inside the motor terminal box must be changed Secondary side is ground x While extracting the conneting cable control of insulation is required date 26 09 2000 Wiring diagram editor Sitter KAE 5 COMPRESSORS D moditication date 55 6 U0024 01 compressor SX 6 7 xs 7 0 stop reset 1 start 51 1 Emergency Stop PB 3 5 start release FAILURE FAILURE S1 motor 52 temperature 3 direction of ratation 54 for additional arrangement 1 lo
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11. E ide esc k reser ae iP KAESER COMPRESSORS terminal connection compressor SX 6 terminal strip TB1 T cs TUE KAESER lay out ASX6 U0024 01 ____ _____ L nane COMPRESSORS compressor 5 6 1 Wiring Diagram screw compressor SX 6 single phase 230V 12 60 manufacturer KAESER COMPRESSORS 96450 COBURG GERMANY consignee customer KAESER cover page DSX6 WE U0019 01 COMPRESSORS compressor SX 6 Input voltage 230V 18 60 L1 6 0 TH A s b c N 0 5 hp compressor motor supply line cross section and fusing see service manual s b c supplied by customer Secondary side is ground While extracting the conneting cable control of insulation is required power on We Fi KAESER wiring diagram SSX6 WE U0019 01 esl 4 1 53 5 start release FAILURE FAILURE 1 motor 52 temperature 53 direction of rotation 4 for additional arrangement release locked SS counter pressure 22 24 PB Orgy ee 22 2 0 50 36 39 27 Emergency Stop Removable jumper KAESER wiring diagram SSX6 WE 00019 01 _____ COMPRESSORS compressor 5X 6 ure rane PT monitors Page i main winding auxiliary winding E KAESER wiring diagram 55 6 U
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13. ane ee ee ees 3 13 3 8 Environmental Protection 3 13 KAESER COMPRESSORS Contents Chapter page 4 Design and 4 14 4 1 Machine Overview ences Ang bce ean RR dera deep na 4 14 4 1 1 Rte Rb Ind eren 4 14 4 1 2 FUNCION uec UE bem qucd Ws 4 14 4 2 Operating States and Control Modes 4 14 4 2 1 4 14 4 2 2 Controller Operation 4 15 4 2 3 Control modes 4 15 4 3 Safety Devices ican cee ee eI ead Ae AR Vee E Y ARAS 4 15 4 4 Safety System oci ete Lco dine da Gat a yaks 4 16 4 4 1 KAESER CONTROL tankers ote tas Gene ce gat 4 16 5 Installation and Operating Conditions 5 17 5 1 Ambient 5 5 17 5 2 Installation Conditions 5 17 5 2 1 Place of installation and space required 5 17 5 2 2 Ventilation does aa mm 5 18 5 2 3 Operating in a compressed air system 5 19 6 I
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18. This indicates important information 2 1 2 2 2 3 KAESER COMPRESSORS Technical Specification Technical Specification Model and important technical information is to be found on the machine nameplate The nameplate is found inside the machine It is fixed to the outside of the control cabinet Please transfer data from the nameplate Model Part no Year Serial no psig cfm Voltage Hz RPM Package FLA Phase HP Wiring Diagram FOR SERVICE REFER TO EQIPMENT NUMBER Tab 1 Nameplate Weight Maximum weight is shown Actual weight of individual machine is dependent on equip ment fitted Weight Ib 267 Tab 2 Weight Temperature Minimum cut in temperature F 40 Typical airend discharge temperature during 167 200 operation airend discharge temp automatic 230 shut down F Tab 3 Machine temperatures Ambient Conditions Maximum elevation ft 3000 Ambient temperature F 40 105 Inlet air cooling air temperature F 40 105 Maximum relative inlet air humidity at 88 F 100 26 Maximum relative inlet air humidity at 105 F 60 26 Higher elevation permissible only after consultation with the manufacturer Tab 4 Ambient Conditions KAESER COMPRESSORS 2 4 2 5 2 6 2 7 2 7 1 Pressure Maximum working pressure see nameplate Minimum
19. quide plotes j guide p Cooling cir outlet 259 ft s Ap 1 32 inch Wc stay suos 1 AINA AAS IN gars ipn jn 6 0 5640 Japan rro anu 245455 49 prs Bunpuazsuo 244 Du y es ung uem UJ jet Je sues Ue JOU im mino af rans mn MILANI quar lias Hen AE MARR 1 sa rigen nissmn 126 n rey fin 127 atn KAESER COMPRESSORS Appendix 13 1 3 Electrical diagram Electrical diagram Description 1 208 3 60 2 230 3 60 or 460 3 60 3 230 1 60 13 70 Wiring Diagram screw compressor SX 6 direct on line start 208V 3 60 manufacturer KAESER COMPRESSORS 96450 COBURG GERMANY consignee customer 5 cover page DSX6 U0016 01 COMPRESSORS compressor SX 6 E pre 0 Input voltage 208V 93 60 s b c zT supply line cross section and fusing see service manual s b c supplied by customer 0 stop reset start 0 Y 1 min Emergency Stop BL T T check Gegner COMPRESSORS modiFicatian date 5 hp 41 compressor motor 13 194 adjusted 16 5A Secon
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21. 4 QUAE KS 491422 1044107 0215552 865070 459 48 040 780750 290 SWVN _ _ _ Wnlv 966 9421 ae sub sUaullp nv abyeyssip bunoo3 jo 434099 jaued juaum4jsu Jo J8 U8j Jy p asap suo3 jou seu skemuoop pue sabessed MoJJeU 5 MONY iNOILN3LLY LdN abveyzsip 9 Dd SUOIYIaUUOD 1 514459 3 abyey sip unbuebnz biw 1 un i b N YJOA 8 8601 auuo 44284 6g sasun 45 85911 9421414425 9 la pun umjua vaqayin ssewal KOMPRESSOREN Overall permitted pressure loss in ducting SX 46 Cooling air i Dunuey igeg 02 122004 Schubart 3 64 int 3 54 inch Wc 5 7 8 x B 3 4 Air ducting Ap 0 018 inch wr Straight duct 118 inch We Angle Ap total 3 32 inch wc total 2 em lt gt e a he gt
22. If no shut off valve is provided the complete air system must be vented Fig 11 Vent the machine 1 Screw 3 Hose coupling air cooler venting oil separator tank venting 2 Pressure gauge 6 Male hose coupling fitting Check that the oil separator tank pressure gauge reads zero psig 3 After automatic venting the pressure gauge does not read zero sure that shut off valve is closed t lf manual venting does not bring the oil separator tank pressure gauge to zero call KAESER service Manually venting the oil separator tank t Plug the male hose fitting 6 into the hose coupling 3 and release the pressure Remove the male hose fitting from the hose coupling Manually venting the compressed air cooler Remove the screws 1 and carefully release pressure t Check that the O ring is correctly seated and tighten the screws 1 Checking and Topping Up the Cooling Oil Checking cooling oil level Pre condition Machine switched off 10 41 10 9 2 Maintenance Fig 12 Checking the cooling oil level Oil level maximum 5b Minimum oil level Wait a few minutes and then check the oil level up as soon as the oil level reaches the minimum 5b Topping up the cooling oil Equipment Cooling oil Pre condition Machine switched off Main disconnect locked out Machine is cooled down Danger of explosion from oils and lub
23. wash off immediately Eye contact rinse thoroughly with lukewarm water and seek medical assistance If necessary request a copy of the safety data sheet for KAESER lubricants Environmental Protection Do not allow cooling oil to escape to the environment into the sewage system Store and dispose of used materials and replaced parts in accordance with local environ ment protection regulations Observe national regulations This applies particularly to parts contaminated with cooling oil 3 13 4 1 2 4 2 4 2 1 KAESER COMPRESSORS Design and Function Design and Function Machine Overview Cabinet The cabinet when closed serves various purposes sound damping protection against contact e cooling air flow control Safe and reliable operation can only be ensured with the cabinet closed To open release the latches with the key supplied with the machine and lift off the canopy Function Items in brackets correspond to the P amp diagram in chapter 13 1 1 Machine Air is drawn in from the surroundings and cleaned as it flows through the filter 1 The air is then compressed in the airend 4 The airend is driven by an electric motor 3 Cooling oil is injected into the airend It lubricates moving parts and forms seal between the rotors themselves and between them and the airend casing The cooling effect directly within the compression chamber ensures a low airend dis
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26. 8 29 8 2 2 Automatic restart 8 29 8 2 3 SWItCHING UR NE 8 29 8 3 Switching in Emergency and Switching On Again 8 29 10 11 12 KAESER COMPRESSORS Contents Chapter page Event Recognition and Fault Rectification 9 30 9 1 Trouble shooting Possible cause Remedy 9 30 9 1 1 Airend temperature is too high greater than 167 F 200 F 9 30 9 1 2 Motor overload relay switches the unit off 9 31 9 1 3 Compressor is running but produces no pressure 9 31 9 1 4 Oil leaks out of air filter 9 32 9 1 5 Full load Idle sequence occurs too frequently short cycles 9 32 9 1 6 Safety relief valve blows off 9 32 9 1 7 Oil inside the unit 9 32 9 1 8 Excessive consumption 9 33 Maintenance 10 34 10 1 Safety 10 34 10 2 Maintenance Schedule 10 35 10 2 1 Regular Maintenance Work 10 35 10 2 2 change intervals
27. t Work carefully Danger from fan wheel AN Danger of serious injury from rotating fan wheel WARNING Touching a rotating fan wheel can result in serious laceration or even sever ance t Do not open the enclosure while the machine is switched on Isolate all phases of the main power supply switch off the mains isolating device Ensure that the power supply cannot be switched on again lock off t Work carefully Further dangers Handling cooling and lubricating fluids Avoid contact with skin and eyes Do not inhale oil mist or vapor Do not eat or drink while handling cooling and lubricating fluids Fire open flame and smoking are strictly forbidden 3 11 KAESER 3 5 6 3 6 Welding When welding is taking place on or near the machine take adequate measures to ensure that no parts of the machine or any oil vapors can ignite because of sparks or heat Spare parts The use of unsuitable parts may adversely influence the safe working of the machine Use only genuine KAESER spares for parts subject to pressure Danger zones The table gives information on the zones dangerous to personnel Only authorized personnel may enter these zones Transport 10 ft radius from the machine Installation or transport per sonnel All personnel excluded dur ing transport Beneath the lifted machine All personnel excluded Installation Within the machine Installation personnel 3 ft radius of
28. 2 to be installed by the user in the connection line the compressed air connection with a flexible hose 1 or an axial compensa tor 1 Electrical Connection Main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC OSHA and any applicable local codes Use wire conductor dimensions and fuse ratings in accordance with local regulations Guide values are given in chapter 2 9 Theuser must provide the machine with a lockable supply disconnecting device This could be for example a disconnect switch with fuses If a circuit breaker is used it must be suitable for the motor starting characteristics Before initial start up The control transformer the control cabinet has connections for various supply volt ages Check that the correct connections are made for the supply voltage provided for the machine If necessary re connect the transformer using the 5 taps to match the supply voltage Connect the machine to the main power supply in accordance with the electrical dia gram in chapter 13 1 3 Changing main voltage connections 230 460V only Equipment The required jumpers also known as bridges or links are provided in the control cabinet Pre condition Machine switched off Main disconnect locked off The standard machine is set up for 230V 3 ph 60 Hz but may be modified for 460V 3 ph 60Hz Th
29. 4 slowly up with oil slowly to the maximum level r Replace the plug gasket if necessary re insert the plug Start the machine and carry out a test run re Close and lock the maintenance canopy Open the user s shut off valve between the machine and the air main r Start the machine and allow to run for ten minutes then switch off check the oil level and top up if necessary re out a visual check for leaks 10 43 KAESER COMPRESSORS Maintenance 10 10 Changing the Cooling Oil Equipment Cooling oil Oil catchment container Thoroughly blow out all the oil from the separator tank and cooler Co Dispose of the old oil in accordance with local environment protection reg ulations Danger of burns from hot components and oil CAUTION Wear long sleeved clothing and gloves t Work carefully Fig 14 Changing the cooling oil oil separator tank 2 Pressure gauge 6 Male hose coupling fitting 3 Hose coupling oil separator tank vent 10 Shut off valve venting line ing 4 Oil filling port with plug 11 Shut off valve oil drain Oil level maximum 5b Minimum oil level Compressed air helps to expel the oil This pressure can be generated by the machine itself Alternatively an external source of compressed air can be used External air is necessary if the machine is not operational isto be restarted after a long standstill period 10 44 K
30. 4 4 Safety System 441 KAESER CONTROL The green light emitting diode LED 5 is illuminated if the compressor unit is running or ready for operation It is off if malfunction is detected A malfunction detected by the control functions 1 2 3 and 4 will shut down the compres sor unit immediately accompanied by an appropriate malfunction light 5 MAESER CONTROL Ih 1 1 Overload protection cutout cuts out if the motor is overloaded Depress the reset button of the overload protection cutout when the fault has been re moved 2 Temperature gauge switch The machine shuts down if the airend discharge temperature reaches 230 F 3 Pressure switch for direction of rotation shuts down the machine if the V belts come off the pulley or tear and at wrong direc tion of rotation 4 Spare 4 16 KAESER 5 5 1 5 2 5 2 1 Installation and Operating Conditions Ambient Conditions There must be no open flames or sparks at the place of installation Any welding work carried out on the equipment must not cause a fire hazard through flying sparks or excessive temperature The machine is not explosion proof Do not operate in areas in which specific requirements with regard to explosion protection are applied Clean inlet air with no damaging contaminants Inlet air free of explosive or chemically unstable gas or vapor Inlet air fr
31. Spares Operating Materials Service 11 52 11 1 Note the 14 52 11 2 Ordering Maintenance Parts and Operating Materials 11 52 11 3 Maintenance Contract 11 52 11 4 Service Addresses ae ee ede bee eens 11 52 11 5 Spare Parts for Service and Repair 11 52 De commissioning Storage and Transport 12 61 12 1 12 61 12 2 am iun tees ute 12 61 12 3 Storage us Pe eee peu bo 12 62 12 4 TRANSPOMING awe Shea eee eee dels 12 62 12 4 1 12 62 12 4 2 Fork 12 62 12 4 3 Transverse beams gros ge Ad 12 63 12 5 Disposal Stee ote tale Sela 12 63 KAESER COMPRESSORS Contents Chapter page 13 Annex 55 2 ad cbe 13 64 13 1 Diagrams and 05 13 64 13 1 1 Pipeline and instrument flow diagram P amp I diagrams 13 64 13 1 2 Dimensional Drawing 13 67 13 1 3 Electrical
32. air can flow back into the machine t De pressurize all pressurized components and enclosures Check all machine hose connectors with a hand held pressure gauge to ensure that all read zero Initial start up may only be carried out by authorized personnel Before switching on ensure that no one is working on the machine all panels are in place and secured all access doors are closed Before Every Initial Start up Initial start up of the machine may only be carried out by trained and authorized installa tion or maintenance personnel Incorrect or improper start up can cause damage to the machine Special measures on starting after storage Storage period longer Action to take than 12 months Change the oil filter gt Change the oil separator cartridge Change the cooling oil rz Have the motor bearings checked by an authorized KAESER distributor 36 months Have the overall technical condition checked by an autho rized KAESER distirbutor 7 3 7 4 7 5 KAESER COMPRESSORS Initial Start up Checking Installation and Operating Conditions Cover all points in the checklist before starting the machine checked Chapter 1 gt Are all conditions for installation in order 5 User s lockable supply disconnecting device installed 64 3 2 re Is the power supply as specified on the nameplate 4 S
33. cfm at 0 4 in wc Exhaust air duct 6 x 13 3 8 Dimensions in Tab 13 Ventilation 5 18 5 2 3 KAESER Exhaust ducting Consult the manufacturer on the design of the ducting length number of bends etc Further information on exhaust air ducts can be found in chapter 13 1 2 Operating in a compressed air system When the machine is connected to an air system the operating pressure must not exceed 230 psig Initial filling of a fully vented air system generally creates a very high rate of flow through air treatment devices These conditions are detrimental to correct air treatment Air quality can be degraded To ensure maintenance of desired air quality when filling a vented air system we recom mend the installation of an air main charging system Please contact KAESER for assistance in selecting and installing an air main charging sys tem 5 19 KAESER COMPRESSORS Installation 6 Installation 6 1 Safety A N Danger of fatal injury from electric shock DANGER Contact with live electric components can cause serious injury or death t Isolate completely from the mains supply switch off the main isolator Ensure that the power supply cannot be switched on again lock off gt Check that no voltage is present AN There is considerable danger of injury or death if insufficiently or inad equately treated compressed air is used DANGER Injury and or contamination can result from bre
34. contact authorized KAESER distributor for options 2 9 2 KAESER SOMEHESSOHS Technical Specification Power supply specifications The following multi strand copper core wires are given according to 2002 NEC 310 15 Table 310 16 for 40 ambient temperature If other local conditions prevail like for example high temperature the cross section should be checked and adjusted according to 2002 NEC 110 146 220 3 310 15 Table 310 16 430 6 430 22 430 24 and other local codes Dual element time delay fuses are selected according to 2002 NEC 240 6 430 52 and tables 430 52 430 148 and 430 150 We strongly suggest using a separate copper conductor for the equipment GROUNDING NEC Table 250 122 will point out the minimum size however we recommend a ground conductor the same size as the power leads if local codes allow Rated power supply Power supply V phase Hz 208 3 60 230 3 60 460 3 60 230 1 60 Supply 10 AWG 12 AWG 14 AWG 8 AWG Consumption TA Tab 11 Electrical connections data KAESER 3 3 1 3 2 3 3 3 3 1 Safety and Responsibility AN Disregarding this notice can result in serious injury DANGER Read the service manual carefully and pay attention to the contents The machine is manufactured to the latest engineering standards and acknowledged safety regulations Nevertheless risk of injury and death for the user and other parties and damage to t
35. cool down completely Disconnect all air and electrical connections Packing Equipment Desiccant Plastic sheeting Wooden transport crate Pre condition Machine is de commissioned Machine is dry and cool Place desiccant inside the machine cabinet te Wrap the machine in plastic sheeting Transport packing A wooden crate is required for overland transport to protect the machine from mechanical damage Consult an authorized KAESER distributor for advice on packing for sea or air transport 12 61 12 3 12 4 12 4 1 12 4 2 KAESER ei De commissioning Storage and Transport Storage Pre condition The machine must be adequately packed Moisture and frost CAUTION Machine damage possible te Store the machine in dry frost free room Prevent entry of moisture and condensation I Advice can be obtained from KAESER on suitable storage and initial start up Moisture can lead to corrosion particularly on the surfaces of the airend and oil separator tank Frozen moisture can damage components diaphragms valevs and gaskets Transporting Safety Transport only by fork truck or lifting cradle and with personnel trained in the safe use of the transport equipment Take weight and center of gravity into consideration The center of gravity is shown in the drawing in chapter 13 1 2 Make sure the danger zone is clear Fork truck Pre condition The whole machine must be over
36. cut in pressure 80 psig Pressure switch factory setting Technical Specification Maximum working pressure psig Cut in Cut out Pressure pressure pressure differential psig psig psig 110 100 110 10 125 115 125 10 145 135 145 10 Tab 5 Pressure switch setting Blow off setting of the safety relief valve Maximum working pressure psig Blow off setting psig 110 140 125 155 145 175 6 Safety relief valve setting Delivery 110 21 125 20 145 17 7 Delivery Sound Level Operational state e under load at rated speed rated delivery and rated pressure Measuring conditions e Free field measurement to CAGI PNEUROP PN8 NTC 2 3 at 1 m distance Sound level dB A 66 Tab 8 Sound Pressure Level Motor and Performance Compressor motor Rated power Hp Rated speed rpm 3600 Enclosure protection TEFC Transfer data from motor nameplate to the table 2 8 2 8 1 Technical Specification Motor bearing greasing operating hours Grease requirement each bearing oz Transfer data from motor nameplate to the table Tab 9 Compressor motor data Cooling oil Ordering see Spare Parts Operating Materials Service chapter 11 Lubrication of an air compressor is essential to reliable operation Carbon and varnish can form in compressor oils These deposits block the flow of lubricant and cause excess
37. is cooled down The life of the oil separator cartridge is influenced by pj o contamination in the air drawn into the compressor Compliance with change intervals of Cooling oil Oil filter Air filter The oil separator cartridge cannot be cleaned Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations 10 49 KAESER COMPRESSORS Maintenance Fig 19 Changing the Oil Separator Cartridge 14 Cover 21 Seal 15 Dirt trap 23 separator cartridge 17 Retaining screw r Remove the cover retaining screws 17 and carefully lift the cover 14 out the old oil separator cartridge 23 together with the gaskets 21 and dispose of according to environmental protection regulations r Clean all sealing faces rr Insert the new oil separator cartridge with gaskets 21 and screw down the cover r Renew the dirt trap 15 strainer and O ring Start the machine and carry out a test run re Close and lock the maintenance canopy Open the user s shut off valve between the machine and the compressed air system Le Switch on at the main disconnect Le After a few minutes of operation stop the machine and check for leaks 10 50 KAESER COMPRESSORS Maintenance 10 14 Logging Maintenance Work Machine number Date Maintenance task carried out Operating hours Signature
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40. second period Reset the timer relay K1 1T to the normal run up period of six seconds before operat ing the compressor further This measure gives the machine enough time to safely fill the oil cooler and the oil circula tion system with oil Idle period timer setting Pre condition Machine switched off Mains power switch off and locked out The idle period timer is located in the control cabinet adjustment range 1 5 30 min Set the idle period so that the motor starting frequency is no more than 15 per hour 7 9 KAESER COMPRESSORS Initial Start up Network pressure switch setting Pressure switch switching differential settting to limit switching frequency The maximum frequency of switching from LOAD to IDLE is two per minute e Pressure adjustment is only possible when the pressure switch is installed and under pressure The starting frequency can be reduced to a certain degree by increasing the switching dif ferential If this measure is not sufficient a larger air receiver should be installed to give more buffer capacity Fig 6 Setting the pressure switch 1 Adjusting screw P 2 Adjusting screw Replace the cover after every adjustment to the pressure switch and before switching on the compressor Increase cut out pressure r Remove the cover of the pressure switch Turn the adjusting screw 1 clockwise with a screwdriver r
41. the forks The diagram shows how the machine should be lifted by a fork truck hA LI Fig 20 Transport by fork truck 12 62 KAESER ei De commissioning Storage and Transport 12 4 3 Transverse beams 12 5 Pre condition The lifting cradle complies with local safety regulations No pressure bears on the sides of the machine cabinet AI Incorrect application of the lifting cradle can damage the machine CAUTION Do attach the lifting cradle to any of the machine components machine manufacturer can advise on application of a suitable lift ing cradle Examples of unsuitable fixing points pipe supports e flanges attached components such as centrifugal separators condensate drains or filters e rain protection covers The diagram shows how the machine should be lifted by a cradle 12 0004 02 Fig 21 Transport with lifting cradle 1 Transverse beams 2 Straps Disposal Pre condition Machine is de commissioned When disposing of a machine drain out all liquids and remove dirty filters Co Parts contaminated with cooling oil must be disposed of in accordance with local environment protection regulations Completely drain the cooling oil from the machine Remove used ail filter and separator cartridge te Hand the machine over to an authorized disposal expert 12 63 KAESER COMPRESSORS Annex 13 An
42. 0019 01 COMPRESSORS compressor SX 6 manet jme mme TE meter connection 3 3FU motor starter motor starter operating capacitor starting capacitor bleeder resistor centrifugally operated switch fuses transformer transformer compressor motor Kaeser Control terminal strip malfunction indicators malfunction lights automatic shutdown motor overload relay excessive temperature switch 230 F safety air pressure switch solenoid valve combined control vent valve time relay start unloading time relay idling control relay hour meter indicating light power on switch 0 stop Reset 1 start emergency stop pushbutton air pressure switch Eno warn este T KAESER B COMPRESSORS component legend compressor SX 6 SSX6 WE U0019 01 control panel 9 5 8 x 16 C 203057 1 B D Description and function Component identification data Order No Component Kt SGKAE 5 2 20s 15 30min 5 TR1 TR2 transformer 2x230V 115V Siemens 7 2220 1 T fuse socket USM 3 Gould 7 3320 00010 1FU 2FU 3FU primary control fuse TRM 1 7 3300 0 1FU 2FU secondary control fuse TRM 1 Gould 7 3300 0 3FU instrument panel eee aoe 115 __ _ _ _ __ ___ __ 4 f control switch with
43. AESER COMPRESSORS Maintenance Changing the oil with help from internal pressure Pre condition The machine has been running at least five minutes under LOAD Machine is switched off Machine fully vented no pressure Pressure gauge on the oil separator tank indicates zero re Close the shut off valve 10 in the venting line re Start the machine in idle and watch the oil separator tank pressure gauge 2 until it reads 40 70 psig Switch the machine off Switch off and lock out the main disconnect switch Wait at least two minutes for oil to flow back to the separator tank Changing the oil with help from an external pressure source Pre condition Machine switched off Main disconnect locked out Machine fully vented no pressure Pressure gauge on the oil separator tank indicates zero External source of compressed air available Close the shut off valve 10 in the venting line Connect the hose coupling 3 to an external air supply Allow air to flow into the oil separator tank until the pressure gauge reads 40 70 psig WW Disconnect the external air supply Draining the oil from the separator tank I Contact KAESER Service if condensate is detected in the oil It is necessary to adjust the airend discharge temperature to suit operating conditions Have an oil container ready Place the end of the oil drain hose in the container and secure it in place Slowly open the sh
44. ING Serious injury is possible Never direct compressed air at persons or animals Damage from machine under temperature CAUTION Frozen condensate and too viscous cooling oil can result in damage when starting the machine Make sure the temperature of the machine is at least 40 F before starting t Heat the compressor room or install an axuliary heater in the compres sor Ensure that one is working on the machine all panels are in place all access doors are closed 8 2 1 8 2 2 8 2 3 8 3 KAESER COMPRESSORS Operation Switching on Switch on at the main supply isolator t the control switch 4 to the lI position The compressor motor starts as soon as the network pressure is lower than the set value cut out pressure Automatic restart System pressure is lower than cut out pressure The machine can restart automatically when power is resumed after a power cut Switching off t the control switch 4 to the 0 position Switch off and lock out the mains power supply switch Switching Off Emergency and Switching On Again Switching off gt Press the EMERGENCY STOP button 6 The EMERGENCY STOP remains latched The compressor is vented and the machine is prevented from re starting Starting again Pre condition Fault rectified Turn the EMERGENCY STOP button in the di
45. RS Maintenance 10 3 10 4 Air Filter Maintenance Equipment Replacement part Pre condition Machine switched off Main disconnect locked out Machine is cooled down 10 0040_01 Fig 8 Air filter maintenance 1 Nut 2 Air filter cartridge 3 Housing Opening the air filter housing te Unscrew the nut 1 on the housing 3 t Lift up the housing and remove the filter element 2 Cleaning the element by tapping Renew the cartridge after two years or after it has been cleaned five times t the element at the end a number of times with the palm of the hand t Clean the sealing faces Cleaning the element with compressed air gt Usedry compressed air lt 70 psig to blow out the element at a slant from the inside to the outside Closing the air filter housing Clean all parts and sealing surfaces Insert the new filter element 2 in the housing 3 Attach the casing 3 with the nut 1 to the inlet valve Close and lock the maintenance canopy Filter Mat Maintenance Equipment Warm water and household detergent Spare parts as required Pre condition Machine switched off Main disconnect locked out 10 37 10 5 10 6 KAESER COMPRESSORS Maintenance Fig 9 Filter mat 1 Filter mat 2 Mounting frame 3 Fixing Removing the filter mat The filter mat can be removed with a screwdriver Carefully loosen the fixings 3 and remove the mounti
46. SERVICE MANUAL Screw Compressor Model SX 6 classic 9 5758 00USE KAESER COMPRESSORS Contents Chapter page 1 Regarding this Document 1 1 1 1 Handling the Document 1 1 1 2 Further Documents 1 1 1 3 CODVEFIGIL ead rea staan 1 1 1 4 Symbols and Identifications 1 1 1 4 1 Warning notices 1 1 1 4 2 Miscellaneous notices and symbols 1 2 2 Technical Specification 2 3 2 1 Weight RR whe noe Fed tA rud 2 3 2 2 Temperature cie chy pew pneter EC Ou Risa m Do 2 3 2 3 Ambient 5 2 3 2 4 Pressure 3 os eb b te ur 2 4 2 5 Delivery xo Ad MP ERES REB PURSE 2 4 2 6 Sound 2 4 2 7 Motor and Performance 2 4 2 7 1 Compressor Motors sv easy vans edgar Re REL dd ears 2 4 2 8 Cooling OIL 2 5 2 8 1 General 2 5 2 8 2 Cooling quantity 2 6 2 9 Electrical Connecti
47. and regulations relating to refrigeration equipment for machines with refrigeration dryers e mustbe able to recognize the possible dangers of electrical and compressed air de vices and take appropriate measures to safeguard persons and property e mustbe able to recognize the possible dangers of refrigeration devices and take ap propriate measures to safeguard persons and property for machines with refrigeration dryers e must have received adequate training and authorisation for installation and mainte nance on these particular machines Adhere to inspection schedules and accident prevention regulations The machine is subject to local inspection schedules Safety Devices Do not change bypass or disable safety devices Do not remove or obliterate labels and notices Ensure that labels and notices are clearly legible More information on safety devices is contained in chapter 4 Design and Function sec tion 4 3 Safety Devices Hazards Always observe approved safety regulations as a basic principle Observe approved safety regulations and national legislation applicable to all work carried out on the machine Examples of these are directives and national regulations concerning safety and accident prevention 3 5 1 3 5 2 KAESER Danger from electricity Electric voltage DANGER Touching electrically energized components can cause serious injury or death Isolate all phases from the pow
48. athing compressed air Contamination of food can result from using untreated compressed air for food processing from this machine must meet 29CFR1910 134 and FDA 21CFR178 3570 standards if used for breathing or food process ing Use proper compressed air treatment Food grade coolant must be used for food processing Compressed air can cause injury or death WARNING Serious injury or death can result from loosening or opening components under pressure t De pressurize all pressurized components and enclosures AN There is considerable danger of injury or death if spring loaded com ponents are incorrectly opened dismantled WARNING Minimum pressure check valves safety relief valve and inlet valve are hea spring loaded t Do open dismantle valves Installation work may only be carried out by authorised personnel All functioning parts are factory set Changes may not be made without the permission of the manufacturer 6 2 Report Transport Damage Check the machine for visible and hidden transport damage Inform the carrier and the manufacturer in writing of any damage KAESER COMPRESSORS Installation 6 3 6 4 6 4 1 Install the Compressed Air Connection Pre condition air system completely vented 06 0001 2 1 3 Compressed Air Connection Axial compensator or flexible hose Shut off valve Shut off valve
49. ation maintenance and repair of the machine These are for example valid national laws and safety and accident preven tion regulations Give clear instructions on reporting faults and damage to the machine Components removed from the machine can still be dangerous All components removed from the machine must be treated or disposed of in accordance with safety regulations e g the inlet valve is heavily spring loaded Qualified personnel Ensure that operating installation and maintenance personnel are qualified and authorized for their tasks 3 4 3 5 KAESER Operating personnel Authorized operating personnel must be adult e must be conversant with and adhere to the safety instructions and sections of the ser vice manual relevant to operation of the machine e musthave received adequate training and authorisation to operate electrical and com pressed air devices e musthave adequate training and authorisation to operate refrigeration equipment for machines with refrigeration dryers Installation and maintenance personnel Authorized installation and maintenance personnel e must be adult e mustbe conversant with and adhere to the safety instructions and sections of the ser vice manual relevant to installation and maintenance of the machine e must be fully conversant with the safety concepts and regulations of electrical and compressed air engineering e mustbe conversant with safety concepts
50. carefully 1 Fig 16 Changing the oil filter 1 Oilfilter 2 Direction to unscrew 10 46 10 12 KAESER COMPRESSORS Maintenance Co Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations te Unscrew the oil filter anti clockwise catch oil spillage and dispose of correctly t Lightly oil the new oil filter gasket e Screw the new filter using hand pressure only Do not use any tool Turn the oil filter clockwise to tighten Start the machine and carry out a test run Close and lock the maintenance canopy Open the user s shut off valve between the machine and the compressed air system Switch on at the main supply isolator Switch the machine on After about five minutes check the oil level and top up again if necessary Y Y q YY Carry out a visual check for leaks Cooler Maintenance Equipment Cleaning rags High pressure cleaner Pre condition Machine switched off Machine fully vented no pressure Pressure gauge on the oil separator tank indicates zero Main diconnect locked out Machine is cooled down Check the cooler regularly for contamination Frequency is mainly dependant on local op erating conditions e Contamination causes overheating and machine damage 10 47 KAESER COMPRESSORS Maintenance Remove the cooler Fig 17 Cooler with fixings 2 Fitting t Loosen the fitting 2 and catc
51. charge temperature Cooling oil is recovered from the compressed air in the oil separator tank 6 gives up its heat in the oil cooler 11 The oil then flows through the oil filter 10 and back to the point of injection Pressure within the machine keeps the oil circulating A separate pump is not necessary A thermostatic valve maintains optimum oil temperature Compressed air freed of its oil content in the separator tank flows through the minimum pressure check valve into the aftercooler 13 The minimum pressure check valve 12 en sures there is always sufficient internal pressure to maintain cooling oil circulation The aftercooler brings down the compressed air temperature to 5 to 10 K above ambient Most of the moisture carried in the air is removed in the aftercooler Operating States and Control Modes Operating states There are three operating states e LOAD the inlet valve is open The airend delivers compressed air to the system The compressor motor runs under full load IDLING 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 valve The compressor motor runs without load and draws little current STANDSTILL The inlet valve is closed The minimum pressure check valve shuts off the oi
52. cked 55 counter pressure 22 21 36 Emergency Stop Removable jumper 60 date 26 09 2000 wiring diagram KAESER 55 6 00024 01 Gegner COMPRESSORS compressor SX 6 Pme oz 1FU 2FU 3FU motor starter primary control fuse secondary control fuse transformer compressor motor Kaeser Control terminal strip malfunction indicators malfunction lights automatic shutdown motor overload relay motor overload relay connection 230V excessive temperature switch 230 F safety air pressure switch component legend solenoid valve combined control vent valve time relay start unloading time relay idling control relay hour meter indicating light power on switch 0 stop Reset 1 start emergency stop pushbutton air pressure switch 55 6 U0024 01 date 26 09 2000 editor Sitter KAESER compressor SX 6 Description and function Component identification data 9 5 8 x 16 26 30 10 89 5 01 TA 25 DU 8 5 DB 25 25A 227 SGKAE 5 2x230V 115V USM 3 ATQ 0 5 TRM 1 TRM 1 control panel motor starter 15 50 60Cy auxiliary switch KC ABB ABB motor overload relay 6 8 5 adapter A 2 205 1 5 30 Scharco 100 3pol Gould 0 5A Gould 10A Gould 10A Gould Wieland control
53. dary side is ground While extracting the conneting cable tontrol of insulation is required power on wiring diagram SSX6 U0016 01 compressor SX 6 53 start release FAILURE release locked 55 counter pressure TR2 noH 15 16 27 FAILURE 51 motor 54 52 temperature 53 direction of rotation 54 for additional arrangement A2 50 36 39 Emergency Stop PB Removable jumper wiring diagram compressor SX 6 KAESER COMPRESSORS check Gegner modificatian date function monitors 14 7 Gor 15 0 55 6 00016 01 Tre 1M motor starter 1FU 2FU 3FU primary control fuse secondary control fuse transformer compressor motor Kaeser Control terminal strip malfunction indicators malfunction lights automatic shutdown motor overload relay excessive temperature switch 230 F safety air pressure switch component legend compressor SX 6 KAESER COMPRESSORS check Gegner modificatian date solenoid valve combined control vent valve time relay start unloading time relay idling control relay hour meter indicating light power on stop Reset start switch emergency stop pushbutton air pressure switch 55 6 0016 01 Pe gt Descriptio
54. diagram 13 70 KAESER COMPRESSORS Directory of Illustrations Chapter page Fig 1 Three phase star four wire earthed neutral 2 6 Fig 2 Three phase star three wire earthed neutral 2 6 Fig 3 Compressed Air Connection 6 21 Fig 4 Drive motor terminal box and overload protection relay 6 22 Fig 5 Inlet valve filling 7 25 Fig 6 Setting the pressure switch 7 26 Fig 7 GControlpanel bien eee T 8 28 Fig 8 Air filter maintenance 1 10 37 Fig 9 Filter le ERO pede xe abe 10 38 Fig 10 Maintain the drive belts 10 39 Fig 11 Ventthe machine 10 41 Fig 12 Checking the cooling oil level 10 42 Fig 13 Venting the 10 43 Fig 14 Changing the cooling oil oil separator 10 44 Fig 15 Changing the cooling oil 10 45 Fig 16 Changing the filter
55. e following parts have to be considered for making the change e Jumpers in the drive motor terminal box Drive motor overload protection relay located in the control cabinet KAESER COMPRESSORS Installation Motor terminal box Motor terminal box Low voltage High voltage 230V Control panel Control panel Fig 4 Drive motor terminal box and overload protection relay Changing the jumpers in the drive motor terminal box Open the terminal box and change the jumpers as shown in the electrical diagram Adjusting the overload protection relay Pre setting Set Point Overload Relay 2304 3 ph TOL and 202 1601 3 ph A Tab 14 Overload protection relay settings t Open the control cabinet and check the overload protection relay pre setting KAESER COMPRESSORS 7 7 1 7 2 Initial Start up Initial Start up Safety Danger of fatal injury from electric shock DANGER Contact with live electric components can cause serious injury or death t Isolate all phases of the main power supply switch off the main isolator t Ensure that the power supply cannot be switched on again lock off Check that no voltage is present Compressed air can cause injury death WARNING Serious injury or death can result from loosening or opening components under pressure Close shut off valves or otherwise isolate the machine from the com opressed air system to ensure that no compressed
56. e that no compressed air can flow back into the ma chine t De pressurize all pressurized components and enclosures Check all machine hose connectors with hand held pressure gauge to ensure that all read zero 3 10 3 5 3 3 5 4 3 5 5 KAESER Extension or modification of the compressed air supply system If compressed air installation is extended or modified check the blow off capacity of the safety relief valves on air receivers and pipelines before installing the new machines Safety relief valves of insufficient blowoff capacity must be replaced by valves with a higher capacity Danger from spring force Springs under tension represent contained force Uncontrolled release of this force can cause serious injury or death There is considerable danger of injury or death if spring loaded com ponents are incorrectly opened WARNING Minimum pressure check valves pressure relief valves and inlet valves are powerfully spring loaded t Do open or dismantle valves Danger from rotating parts Danger from belt drive Danger of serious injury from rotating belt drive WARNING Touching the rotating belt drive can result in severe crushing or even sever ance t Do not open the casing while the machine is switched Isolate all phases from the power supply all conductors switch off the main isolator Ensure that the power supply cannot be switched on again lock off
57. ecommendations only and should be adjusted to suit the installation and operating conditions Keep alog of all service work This enables the frequency of individual maintenance tasks and deviations from KAESER s recommendations to be determined A prepared list is provided in chapter 10 14 Regular Maintenance Work I When operating conditions are unfavorable e g dusty atmosphere or when the equipment is in frequent use maintenance tasks must be carried out more frequently erai Maintenance tasks weekly Check cooling oil level 10 9 1 Clean or replace the filter mats 200 hours after in Change the oil filter 10 11 itial start up Every 500 hours Check and re tension drive belts Every 1000 hours Oil and air cooler maintenance 10 12 Up to 3000 hours Air filter maintenance Up to 3000 hours Change the oil filter 10 11 at least annually Up to 3000 hours Change the oil separator cartridge 10 13 at least every 3 years Up to 12000 hours Change the drive belts 10 7 2 at least every 3 years variable see Change the cooling oil 10 10 chapter 10 2 2 annually Check that all electrical connections are tight Check the safety relief valve 10 6 Have KAESER service check the overheating shut down function Check the oil and air coolers for leaks h operating hours Tab 16 Regular Maintenance Work 10 35 KAESER COMPRESSORS Maintenance 10 2 2 change intervals The dut
58. ed on the pressure scale indicates the pressure Replace the cover of the pressure switch Decrease cut out pressure Remove the cover of the pressure switch Turn the adjusting screw 1 anticlockwise with a screwdriver red pin on the pres sure scale indicates the pressure Replace the cover of the pressure switch KAESER COMPRESSORS Initial Start up To increase the pressure differential between cut in and cut out Remove the cover of the pressure switch Turn the adjusting screw 2 clockwise with screwdriver The black pin on the differ ential pressure scale moves towards r Replace the cover of the pressure switch To decrease the pressure differential between cut in and cut out Remove the cover of the pressure switch rr the adjusting screw 2 anticlockwise with a screwdriver The black pin on the dif ferential pressure scale moves towards Replace the cover of the pressure switch KAESER COMPRESSORS Operation 8 Operation 8 1 Control Panel Fig 7 Control panel 1 Pressure gauge 4 0 1 control switch 2 Hemote contact thermometer 5 KAESEH CONTROL 3 Service hours counter 6 EMERGENCY STOP pushbutton 8 2 Switching On and Off Always use the control switch 4 to switch the machine on and off The supply disconnecting device is installed by the user Compressed air can cause serious injury WARN
59. ee of acid forming substances particulatly ammmonia chlorine or hydrosul phide Ambient temperature must be acceptable and stable airend discharge temperature must remain constant to prevent the build up of condensate Suitable fire extinguishing material must be readily available Installation Conditions Place of installation and space required The floor must be level firm and able to bear the weight of the equipment If installed outdoors the equipment must be protected from cold temperature direct sunlight dust and rain 5 17 KAESER 1 Exhaust ventilator 2 S Air inlet Exhaust 1 opening channel lt bi lt T y 28 UZ7ZZA 7777777777 7 i 8 Exhaust gt i channel lt p ae min 90 m min 90 Measurements in inches 5 2 2 Ventilation Values given are minimum guidelines I If the inlet aperture is insufficient a dangerous vacuum can be created in the compressor room gt Ensure that the volume of air flowing into the compressor room is at least equivalent to that being removed from it by the compressor and exhaust fan Make sure that the machine and exhaust fan only operate when the inlet aperture is actually open Inlet opening sq ft 1 1 Forced ventilation with exhaust venti 590 lator Flow rate
60. ej ugioisod jse alas Jequinu lenas uenbipui sou 59 oiquieoaJ opueno i NOIONALY eogid e e 19 np ON ep asedde ap duo jeuojeui ON 9119 e 5999 ep anbeuo ans Jenbipu 5 i NOLLN3 LLV Jaquinu Wed usum ped jo uonduosep eui pue Jequinu eui jo Jequinu jenos pue i NOLLN3 LIV OJ9poIN 91151212513 Bunuuoiezeg pun Jeu unusuoinisog eios ed L pun ense BunjeiseqiieiziesJ3 sap aig japon i 9NNLHOV oIquie29J sezaid 581 ap epuefe A 4 sezoid 581 2151 adh seDeyoeg JL SIA E 9 1 sooeid 91517 MeJos sabeyoed eoueuejulelA 59 d pue sued areds 2 151 l eds
61. er supply all conductors switch off at the main isolator Ensure that the power supply cannot be switched on again lock off Check that no voltage is present Before the machine is switched on for the first time the user must provide and check mea sures to guard against electric shock by direct or indirect contact Hazards from compressed air Hazard from compressed air quality The compressed air from this machine may not be used without taking appropriate precau tions breathing air e for processing food products AN Unsuitably treated compressed air can cause injury or death DANGER Injury and or contamination can result from breathing compressed air Contamination of food products when they are processed using unsuitable compressed air t Never breath untreated compressed air Air from this compressor must meet 29CFR1910 134 and FDA 21CFR178 3570 standards if used for breathing or food process ing Use proper compressed air treatment Food grade coolant must be used for food processing Hazards from compressive forces Compressed air is a contained force Uncontrolled release of this force can cause serious injury or death Severe injury or death from released compressive forces WARNING Serious injury or death can result from loosening or opening components under pressure Close shut off valves or otherwise isolate the machine from the air main to ensur
62. erential across car tridge Replace cartridge and dirt trap strainer if necessary Check ball valve in vent line and open if it is closed Check the diaphragm in the vent valve and replace if defective Check the minimum pressure check valve Adjust minimum pressure func tion or replace defective parts as ne Check airend and replace if defective Provide adequate compressor ventila tion Repair or replace motor Compressor is running but produces no pressure Possible cause Inlet valve does not open or opens only partially Vent valve does not close at full load Minimum pressure check valve is de fective Air leak in unit Leaks in plant system Plant system air demand exceeds ca pacity of compressor Socket is still in the hose coupling at the oil separator tank or aftercooler Safety relief valve has blown off Coupling defective or V belt broken Remedy Check the inlet valve control valve and lines Replace defective parts as needed Check the combined control vent valve and control lines Replace defective parts as needed Check the valve and replace defective parts Tighten loose connections repair or replace defective parts as necessary Check for open valves loose connec tions defective tools etc Reduce system demand or install additional compressor s Remove socket from coupling See chapter 9 1 6 Check coupling V belt and replace as
63. h any oil running out with the cleaning rags Fig 18 Cooler fixing 4 Screw Remove the screws 4 t Liftthe cooler carefully out of the machine t Close off all openings Clean the cooler e I Observe all safety precautions when working with the high pressure cleaner o Clean the cooler only at a proper cleaning point equipped with an oil water separator Avoid blowing dirt and dust in the air Wear a face mask if necessary 10 48 10 13 KAESER COMPRESSORS Maintenance Do not use sharp objects to clean the cooler The cooler could be damaged Lp y y Ww y Re Clean the cooler with a jet of water or steam Open and clean connections Drain out any water that has entered mount the cooler Lift the cooler carefully into the machine and secure with screws 4 the fittings 2 Start the machine and carry out a test run Fill with cooling oil Close and lock the maintenance canopy Open the user s shut off valve between the machine and the compressed air system After about ten minutes check the oil level and top up if necessary Switch machine off and check for leaks Changing the Oil Separator Cartridge Equipment Replacement part Cleaning rags Pre condition Machine switched off Main disconnect locked out Machine fully vented no pressure Pressure gauge on the oil separator tank indicates zero Machine
64. he machine and other property can arise from its use 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 In particular immediately rectify have rectified any faults that could be detrimental to safety Proper Use The machine is intended solely for industrial use in generating compressed air Any other use is considered incorrect The manufacturer is not liable for any damages resulting from such unspecified use or application The responsibility in case lies solely with the user Proper use also includes compliance with the instructions in this manual Improper Use Never direct compressed air at persons or animals Do not use untreated compressed air for breathing purposes Do not use untreated compressed for any application that will bring it into direct contact with foodstuffs 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 the warmed cool ing air should be treated to render it harmless Do not allow the machine to take in toxic acidic flammable of explosive gases or vapors Do not operate the machine in areas in which specific requirements with regard to explo sion protection are applied User s Responsibilities Observe the relevant regulations during installation oper
65. ice and Repair I Any inspection maintenance or repair tasks not described in this manual should be carried out by an authorized KAESER distributor With the help of this parts list you can obtain in advance the spares you need in accord ance with your operating conditions Spare parts list Description 1 SX three phase 2 SX single phase 11 52 9195 oqwga sezaid 9195 ON sej op ej ugioisod jse alas Jequinu lenas uenbipui sou 59 oiquieoaJ opueno i NOIONALY eogid e e 19 np ON ep asedde ap duo jeuojeui ON 9119 e 5999 ep anbeuo ans Jenbipu 5 i NOLLN3 LLV Jaquinu Wed usum ped jo uonduosep eui pue Jequinu eui jo Jequinu jenos pue i NOLLN3 LIV OJ9poIN 91151212513 Bunuuoiezeg pun Jeu unusuoinisog eios ed L pun ense BunjeiseqiieiziesJ3 sap aig japon i 9NNLHOV
66. indicator light 5 emergency stop pushbutton 1SFA616502R4051 7 3290 10010 1 1 2 1 pm i me Z ETT Ex EE When ordering spare parts include all the information in columnes B C and D and nameplate of compressor 4 KAESER electrical component parts list GSX6 WE U0019 01 oes COMPRESSORS compressor SX 6 are ME table no destination terminal strip destination external inside J 3x16 AWG 8 1 3x16 AWG 8 1 4x16 AWG W591 NYsLY8 2x16 AWG W594 2x16 AwG terminal legend jumper wire connection terminal no link terminal strip 1 total 32 terminals 12 32W cable no name of device connection device legend T MAL EN EN col a HAPS 14 19 xis ars GR SAPS 2 m 4 R0 o i ao 2 so gt 4 GRD GRO m un 5 55 a u fw control mi
67. ion or add a cabinet heater Provide required amount of ventilation Consult authorized KAESER distributor for duct requirements Clean with compressed air water or steam injector Inspect heat exchanger elements Clean or replace as necessary Check oil level and add necessary amount of recommended oil Check dirt trap strainer in oil return line for possible contamination Check the valve spring and actuating piston Replace defective parts Check idle pressure at the separator tank If the pressure is low check the inlet valve Adjust inlet valve to main tain adequate idle pressure Drain old oil completely and replace with recommended type Consult authorized KAESER distributor for other oil types not listed Replace filter Check airend and replace if defective Possible cause Overload relay is defective or setting is wrong Motor is running two phase defective motor or blown fuse Oil separator cartridge is contamina ted Motor starts against pressure because system does not get vented Airend is defective Ambient temperature is above 104 F Defective motor bad bearings or short circuit in windings KAESER Motor overload relay switches the unit off Remedy Check line current and adjust overload relay as necessary Replace relay if defective Check input power check wiring tigh ten any loose connections Replace fuse s or motor if necessary Check pressure diff
68. ive wear and failure of moving parts Contamination of the lubricant can allow the formation of acids causing extensive internal corrosion Water may be condensed decreasing the lu bricity Lubricants in rotary compressors do much more than lubricate During the compression process it acts as a sealant in the airend which is important for maximum efficiency The lubricant also absorbs much of the heat of compression to cool the airend and reduce the temperature of the compressed air It s not enough that a compressor cooling oil lubricates well it must stand up to the heat pressure and contaminants that are present in every air compressor General Information KAESER synthetic lubricants should be stored in a protected location to prevent contami nation Do not re use drums flush and send to reconditioner Although the KAESER synthetic is not highly flammable it will burn While KAESER syn thetic compressor oil is less flammable than equal viscosity mineral oils it cannot be classi fied as a fire resistant fluid It has a flash point above 460 F Since the user has total con trol over the conditions of the compressor lubricant he assumes total responsibility for its safe usage Material Safety Data Sheets are available for each lubricant from your KAESER authorized distributors Regardless of the lubricant selected the KAESER Sigma lubricants will separate readily from water If condensate occurs it can easily be removed Le
69. l lines inlet valve and combined control vent valve Replace defective parts as needed Check the cartridge pressure differen tial and replace cartridge if necessary Check the valve for blockage and re place defective parts as necessary Check blow off pressure and com pare to name plate of the compressor Replace if necessary Remedy Remove the socket from the coupling See chapter 9 1 6 See chapter 9 1 4 Tighten coupling or replace as needed Replace oil cooler KAESER 9 1 8 Excessive oil consumption Possible cause Remedy Wrong oil is being used in the unit Replace with correct oil type Consult authorized KAESER distributor for other oil types not listed Oil separator cartridge has ruptured Check pressure differential and re place oil separator cartridge if neces sary Oil separator cartridge mountings are Tighten mounting bolts loose Oil level in separator tank is too high Drain oil to correct level Scavenger line is clogged Inspect dirt trap strainer in scavenger line Clean or replace clogged parts as necessary KAESER COMPRESSORS Maintenance 10 Maintenance 101 Safety Disregarding these notes and or improper handling may result in serious injury A N Electric voltage DANGER Touching electrically live components can cause serious injury or death Isolate completely from the main supply all conductors switch off at the main disconnect t Ensure that the
70. l separator from the air system The oil separator tank is vented The compresor motor is stopped 4 14 KAESER COMPRESSORS Design and Function 4 2 2 4 2 3 4 3 Controller Operation Using the selected control mode the controller switches the compressor between its vari ous operational states in order to compensate for air being drawn of by consumers and maintain system pressure between the set minimum and maximum values Control modes Only the following control modes are available e DUAL DUAL In the DUAL control mode the compressor is switched back and forth between full load and idle to maintain system pressure between the set minimum and maximum values When the maximum pressure is reached the machine switches to idle running When the preset idling time has elapsed the machine is STOPPED Safety Devices The following safety devices are provided and may not be modified EMERGENCY STOP button The EMERGENCY STOP button shuts down the compressor immediately The motor remains still The pressure system is vented e Safety relief valve The safety relief valve protects the system from excessive pressure This is factory set e Temperature gauge switch The temperature gauge switch protects the machine from overheating The machine shuts down if the airend discharge temperature reaches 230 F e Housing and covers for moving parts and electrical connections Protection from accidental contact 4 15 KAESER
71. n and function Component identification data Order No Component 30 30 10 89 115 50 60Cy 157500010 1M motor overload relay TA 25 DU 19 13 19A ABB 7 5773 0 10L oF 8 8 TR1 TR2 T 1FU 2FU 3FU 1FU 2FU 3FU 1 instrument panel 01 ETS uw EN E 2 EN Ed NN NEN mu m EM RN NN m NN NEN m When ordering spare parts include all the information columnes B and D and nameplate of compressor SER electrical component parts list GSX6 0016 01 sitter check Gegner COMPRESSORS compressor SX 6 5 F modification date age 1 er R tinati Tableto destination terminal strip des ion external inside 6 1 4x16 AWG amp x16 AWG name of device connection terminal no terminal legend jumper wire name of device connection terminal strip 1 device legend total 30 terminals device legend mergency Stop D 1 2 3 1 5 2 TRI 8 5 2 2 D D 20 R T 1 9 01 54 2 2 2 R Es M ETS GR un un un un on un un uo uo oo oo wife fw 5 5 Removable jumper
72. n the shut off valve between the compressor and the compressed air system Maintain the Drive Belts Check the belts and their tension Pre condition Machine switched off Main disconnect locked out Machine is cooled down Check belts after the first 24 hours of operation 3 2 Nut 3 Indicator pin Check for damage I Change any damaged belts immediately tx Turn the pulley by hand so that all of the belt can be inspected for damage Check belt tension and adjust if necessary The automatic tensioner uses spring force to apply correct tension to the belts 10 39 KAESER COMPRESSORS Maintenance 10 7 2 10 8 Adjustment must be made when the indicator pin 3 reaches the top of the elongated hole t Loosen the locking nut 2 Use the adhusting nut 1 to adjust spring tension until the indicator 3 reaches the lower end of the elongated hole t Retighten the locking nut 2 Changing the belts gt Loosen the locking nut 2 r Turn adjusting nut 1 to loosen the tension on the belts until they can be removed from the pulley Install the new set of belts and use the adhusting nut 1 to adjust tension until the in dicator pin 3 reaches the lower end of the elongated hole r Retighten the locking nut 2 re Check tension after the new belts have been in operation for 24 hours Vent the Machine Manually Equipment Male hose fittings located in the control cabinet P
73. necessary 9 1 4 9 1 5 9 1 6 9 1 7 Oil leaks out of air filter Possible cause Oil level in separator tank is too high Inlet valve faulty KAESER Remedy Drain oil to correct level Find the fault and replace the defective part Full load Idle sequence occurs too frequently short cycles Possible cause Receiver tank size is too small or there is no tank Diameter of hose connecting the unit to the receiver tank is too small Minimum pressure check valve leaks Flow is restricted at discharge Safety relief valve blows off Possible cause System does not discharge at idle Oil separator cartridge is contamina ted Minimum pressure check valve does not open Safety relief valve not properly sized for the pressure of the compressor unit Oil inside the unit Possible cause Socket is still in the hose coupling at the separator tank Safety valve has blown off Oil is coming out of air filter Hose coupling on separator tank is loose Oil cooler leaks Remedy Consult authorized KAESER distributor for recommended tank size Connecting hose diameter should not be smaller than the air discharge pipe diameter Install larger hose if neces sary Check the valve and replace defective parts Look for plugged filters partially closed valves frozen pipes or malfunc tioning pressure regulators Remedy Make sure ball valve in vent line is open Check the contro
74. nex 13 1 Diagrams and Drawings 13 1 1 Pipeline and instrument flow diagram diagrams 13 64 1002000 115 5 EEE SE ee ee XS N3s0S S 384 dA OM 5706 12d uS 1V3 SW ue ano passaudwoj 0002000 1159 54 Bunudsun 248543 24253 xs 340552 4403 1 35 900 L0702000 11SXS4 994 Ajajes aJnssaJd uaj s g Jaonpsue J aJnssaJd jio 5 6 1461 0 4920911 10 110 1145 440 4145 apis asoy 6L apis 10 Burjdno3 asoy 1041449 gl aunssaJg DurjusA o4ju02 JojeJedas 10 91220 105495 001 4 1 10 40142404 uoij3aJip 5 55 JBUIE ILS aJnssaJd wnwiuly 191002 10 J040u BAG 18410 10 Snyd maas juod 10 4911044402 aJnjeJaduia 10 1914 sDpijjJe JojeJedas 10 KAESER COMPRESSORS Appendix 13 1 2 Dimensional Drawing 13 67 Gy Jeqn snu Bunuyaiez uabunsepuy sjbuipsqsbunppim4u3 46 90 0 5 667 1 321 251 13190 wo CCG HE EEE
75. ng frame Remove the filter mat Cleaning the filter mat Gently beat the mat or use a vacuum cleaner If necessary wash with lukewarm water and household detergent I Renew the mat if cleaning is not possible of has already been carried out five times Replacing the filter mat t Lay the mat in the mounting frame and fix it in position Electric Motor Maintenance Compressor motor The bearings of the compressor motor are permanently greased Checking the Safety Relief Valve on the Oil Separator Tank To check the relief valve s activating pressure it must be subjected to a pressure higher than the maximum set on the air pressure switch t Switch the machine off gt Close the user s shut off valve between the compressor package and the com pressed air system Open the maintenance canopy Close the shut off valve 10 Fig 14 in the venting line 10 38 10 7 10 7 1 KAESER COMPRESSORS Maintenance Close and lock the maintenance canopy Start the machine and allow it to switch from LOAD to IDLE Since the venting line is closed pressure in the oil separator tank will rise slowly to the re lief valve blow off pressure The blow off pressure can be read from the pressure gauge on the control panel Switch the machine off Open the maintenance canopy Open the shut off valve in the venting line Close and lock the maintenance canopy WWW Ope
76. ng instructions for the pressure vessel e manufacturer s declaration or declaration of conformity in accordance with applicable directives Make sure all documents are at hand and their contents understood Request the supply of any missing documents from KAESER Make sure you give the data from the nameplate Copyright This service manual is copyright protected Inquiries regarding use or duplication of the documentation should be referred to KAESER Symbols and Identifications Warning notices AN Here is a notice warning of danger DANGER Here are consequences of ignoring the warning notice The word indicates that death or severe injury can result from ig noring the notice Always read and diligently comply with warning notices Danger levels Warning notices indicate three levels of danger identified by the signal word under the dan ger symbol Signal word Meaning 7 Consequences of ignoring the warning DANGER Warns of imminent threa Death or severe injury or serious damage to tening danger the machine is possible WARNING Warns of possible threate Death or severe injury or serious damage to ning danger the machine is possible CAUTION Warns of a possibly Light injury or slight damage possible dangerous situation KAESER 1 4 2 Miscellaneous notices and symbols is a task to be carried out Do This symbol identifies environmental protection measures DENN
77. nstallation EE 6 20 6 1 Safety ies ER e 6 20 6 2 Report Transport Damage 6 20 6 3 Install the Compressed Air Connection 6 21 6 4 Electrical Connection 6 21 6 4 1 Changing voltage connections 230 460V only 6 21 7 nlllalStart up coo REIR EE ER RR 7 23 7 1 rs or 7 23 7 2 Before Every Initial Start up 7 23 7 3 Checking Installation and Operating Conditions 7 24 7 4 Setting the overload protection cut out 7 24 7 5 Pour cooling oil into 7 24 7 6 Checking Direction of Rotation 7 25 7 7 Adjusting the start time at first 7 25 7 8 Idle period timer setting 7 25 7 9 Network pressure switch setting 7 26 8 Operatlom ust 8 28 8 1 Gontrol Panel 8 28 8 2 Switching aso siu cR UE nin a eee Es 8 28 8 2 1 Switching
78. ons 2 6 2 9 1 Power SUpply 2 sere rue t eerte tabo emus 2 6 2 9 2 Power supply specifications 2 7 3 Safety and Responsibility 3 8 3 1 Proper USC o UM PA age EE 3 8 3 2 Irnproper USO c uic ER gee Ee 3 8 3 3 User s Responsibilities 3 8 3 3 1 Qualified personnel 3 8 3 4 Safety Devices 3 9 3 5 gt peu ee E NU 3 9 3 5 1 Danger from electricity 3 10 3 5 2 Hazards from compressed air 3 10 3 5 3 Danger from spring force 3 11 3 5 4 Danger from rotating parts 3 11 3 5 5 Further darigers ek eee Sec NR EY VES 3 11 3 5 6 Danger ZONES ec ERE Dee pese cenis 3 12 3 6 Warning Symbols 3 12 3 7 Emiergencles eae Het ed guna eode s edi 3 13 3 7 1 Fire SUPIESSION RIED TAN Paha yee bee een eee de 3 13 3 7 2 Cooling
79. p 5 ep ep eiue 2 9159 ugioeuBiseq 10 101 138 WH3S3V3 ep yy 1e p udse p dnog shueyoap xne uepn ejqixon Jre p pio4jeg ejnu pUedes aqa ne n oolg JnessipiogeH ne n p ejnu p aedes edednos eDessreJf JnesiA Ido ejinu ejnure essnoyw 1neje nusA ep SPUBLULUOD ep anog 2109 V 9199 nao 59 anog do eDueuoe 2018 Sea 5 ep 18168068914 1018088914 ep ep INEM 9 We gt 2 assen
80. power supply cannot be switched on again lock off gt Check that no voltage is present AN There is considerable danger of injury or death if spring loaded com ponents are incorrectly opened WARNING Minimum pressure check valve safety relief valve and inlet valve are hea spring loaded t Do open or dismantle valves Call for authorized KAESER distributor if a fault occurs UN Compressed air can cause injury or death WARNING Serious injury or death can result from loosening or opening components under pressure te Close shut off valves or otherwise isolate the machine from the com pressed air system to ensure that no compressed air can flow back into the machine t De pressurize all pressurized components and enclosures Check machine hose connectors with a hand held pressure gauge to ensure that all read zero Machine damage caused by leakage CAUTION Leaks result in loss of oil and reduced performance Damage or complete breakdown can result t Test run on completion of maintenance work Carry out a visual check of the machine Maintenance work may only be carried out by authorized personnel pj o Before switching on again ensure that e no one is working on the machine all panels in place and secured all access doors are closed 10 34 10 2 10 2 1 KAESER COMPRESSORS Maintenance Maintenance Schedule I Maintenance intervals are r
81. puoo Burreiedo pue ABW e9ueuelulelW M uois ueuugx ueBunBuipegsqeujeg pun ep A e eq eougjsoure sepeJepoui ejseu seoseJJ senjeledule 152 ojorAes ep ep seuoio puoo ue ep eidoud je ep eupiunu p e esseq OJAS je sejueiquue 5 sep Jr ugaja pue jueiquie se yans suonipuoo Buneiedo pue poob ynjBnesuy pun 9 ebigew sio ejunx m ueBunBuipeqsqeneg pun 00055 ayanbeg seJou I 5 u neg 00012 0009 00008 00022 _ 000 00081 00021 0006 0009 0005 9195 oqwga sezaid 9195 ON sej op
82. re condition Machine switched off Main disconnect locked out Machine is cooled down Compressed air can cause injury or death WARNING i 522 Compressed air and devices under pressure injure or cause death if the contained energy of the air is released suddenly or uncontrolled After shutting down the compressor and venting the oil separator tank there is still pressure on the check valve from the compressed air system Close the shut off valve provided by the user to isolate the machine from the compressed air system t Vent the oil separator tank Ventthe air aftercooler to completely depressurize the system between the user s shut off valve and the minimum pressure check valve AI Escaping oil mist is damaging to health CAUTION Do not direct compressed air at a person while venting Do not inhale oil mist or vapour Avoid contact with skin and eyes Before undertaking any maintenance or service work on the pressure system the machine must be isolated from the air system and completely vented 10 40 KAESER COMPRESSORS Maintenance 10 9 10 9 1 The machine is vented in three stages oil circuit vents automatically when the machine is switched off e airis vented manually from the oil separator tank airis vented manually from the air cooler Venting Close the user s shut off valve between the machine and the compressed air system e
83. rection of the arrow to unlatch it Switch the machine on 9 1 KAESER Event Recognition and Fault Rectification Inform KAESER service if the event cannot be rectified by the action suggested Do not attempt rectifications other than those given in this manual Trouble shooting Possible cause Remedy removal of faults that not explicitly described this service manual may only be carried out by KAESER or by an authorised WARNING KAESER service agency Airend temperature is too high greater than 167 200 F Possible cause Cooling air inlet or outlet is too close to wall or other blockage Air intake filter mats are clogged Ambient temperature is too high Ambient temperature too low Cooling air supply is inadequate If cooling air outlet duct is used it may be too narrow or too long On air cooled units the fins of the cool ers oil cooler and air aftercooler are clogged On water cooled units the heat ex changer elements may be clogged Oil level is low Thermostatic valve is not functioning correctly Idle pressure is too low for proper oil circulation Wrong oil is used Oil filter is clogged Airend is defective Remedy Situate unit for adequate air flow Clean the mats or replace if necessary Provide cooler air from other source or move compressor to a cooler location Provide warmer air from other source or move compressor to warmer loca t
84. relay combined time relay t fuse socket ransformer primary control fuse for 460V secondary control fuse rimary control fuse for 230V terminal strip instrument panel ENQ42K 230 F 632 1 10 1SFA616241R4218 1SFA616502R4051 Zander Stork Kaeser Control temperature gauge with switch Bauser ABI ABI hour meter TI5V 60Cy control switch with indicator light B emergency stop pushbutton B mu a m mu NN EN m m NN m m When ordering spare parts include all the information in and 0 and nameplate of compressor date editor mm 26 09 2000 Sitter Gegner KAESER COMPRESSORS compressor SX 6 electrical component parts list D E Order No Component Pismo m 1 1 7 3767 00150 01 E 65 6 10024 01 De device legend 8 1 3x16 AWG 8 1 4x16 AWG 8 1 4x16 AWG connection 460V destinati terminal strip external name of device connection terminal no terminal legend jumper wire location terminal strip TB1 total 30 terminals I T9 M 18 8 destination inside name of device connection cable no device legend DIT mergency Stop GRD ETS control panel
85. rent Pour cooling oil into the inlet port Equipment 0 1 quart cooling oil Pre condition Machine switched off Main disconnect locked out The airend must be manually filled with cooling oil before initial start up and after being out of use for more than 3 months 7 6 7 7 7 8 KAESER COMPRESSORS Initial Start up I Use the same type of oil A sticker giving the type of oil used is found near the oil separator tank filling port 07 0007 01 Fig 5 Inlet valve oil filling port 1 Screw plug 2 Inlet valve t Remove the plug 1 from the inlet valve 2 t Pour oil into the inlet valve and replace the screw plug the rotors over by hand by means of the belt pulley to distribute the oil Checking Direction of Rotation The machine is designed for a clockwise field t Check the supply with a phase sequence indicator Wis d motor turns in the wrong direction change the motor supply phases 1 and L2 I Alternatively the direction of rotation can be checked by briefly switching the machine on and off again Switch the machine off as soon as the direction of rotation is seen and compare it with the direction arrows on the motor and airend Adjusting the start time at first start up t Increase the timer relay K1 1T to 20 seconds for the first start This will prevent com pression of the inlet air during the start up Switch off the compressor just before the end of the set 20
86. ricants WARNING Danger of explosion from ignition of oil mist and vapors Fire open flame and smoking forbidden Damage to the machine from unsuitable oil CAUTION t Never mix different types of oil t up only with the same type of oil as already in the machine Venting Close the user s shut off valve between the machine and the compressed air system I If no shut off valve is provided the complete air system must be vented 10 42 KAESER COMPRESSORS Maintenance Fig 13 Venting the machine 1 Screw 4 Oil filling port with plug air cooler venting 2 Pressure gauge 6 Male hose coupling fitting 3 Hose coupling oil separator tank venting Check that the oil separator tank pressure gauge reads zero I After automatic venting the pressure gauge does not read zero tz sure that the shut off valve is closed If manual venting does not bring the oil separator tank pressure gauge to zero call KAESER Service Manually venting the oil separator tank Plug the male hose fitting 6 into the hose coupling 3 and release the pressure r Remove the male hose fitting from the hose coupling Manually venting the compressed air cooler r Remove the screw 1 and carefully release pressure Tighten the screw 1 rr Close the user s shut off valve between the machine and the compressed air system Topping up the cooling oil re Open the filler plug
87. ry screw compressors in the application where incidental food contact may occur with the discharge air This lubricant meets the requirements of the FDA Regulation 21 CFR 178 3570 and is USDA 1 approved and NSF certified FG 460 is approved for canning food packing meat and poultry processing and other applications where incidental food contact may occur Cooling oil quantity Total volume gal 0 66 Tab 10 Cooling oil volume Electrical Connections See electrical diagrams in chapter 13 1 3 Power supply The machine is designed for an electrical supply according to National Electric Code NEC NEC 670 particulary NFPA 79 section 5 7 In the absence of any user specified alternatives the limits given in these standards must be adhered to Consult manufacturer for any other specific power supply Three phase Do NOT operate package on any unsymmetrical power supply Also do NOT operate pack age on power supplies like for example a three phase open delta or three phase star with non earthed neutral Fig 1 Three phase star wye four wire earthed neutral Fig 2 Three phase star wye three wire earthed neutral The machine requires a symmetrical three phase power supply transformer with a WYE configuration output as shown in Fig 1 and Fig 2 In asymmetrical three phase supply the phase angles and voltages are all the same Other power supplies are not suitable Please
88. t the compressor sit so that any water can drain back to the separator tank and separate to the bottom See chap ter 10 10 proper draining procedure KAESER has several lubricants available that are specially formulated to match these de mands They feature excellent lubricity outstanding demulsibility ability to separate from water and long life M SERIES SEMI SYNTHETIC LUBRICANTS M Series SIGMA compressor cooling oils are the highest quality petroleum lubricants 460 is specially blended to provide reliable performance in KAESER screw com pressors S SERIES SYNTHETIC LUBRICANTS S Series SIGMA compressor oils are formulated from the most advanced synthetic lubricants These synthetic lubricants begin as high quality petroleum feed stock They are then refined processed and purified into fluids with very consistent molecular structure These oils are carefully blended to produce extremely consistant lubricants with superior properties SIGMA synthetic lubricants feature all the advantages of both PAO and diester fluids S 400 lubricant is recommended for compressors operating in ambient temperatures between 40 F and 105 F 2 8 2 2 9 2 9 1 KAESER COMPRESSORS Technical Specification Specialty KAESER LUBRICANTS S 680 lubricant may be used when ambient temperatures are always between 70 F and 105 F e FG 460 synthetic hydrocarbon based food grade lubricant is designed for use rota
89. the machine and power lines Operation 3 ft radius from the machine Operating personnel o Maintenance Within the machine Maintenance personnel 3 ft radius from the machine ae Tab 12 Danger zones Warning Symbols Beware of life threatening electrical voltage rz Do not touch electrical components danger of electric shock Before opening switch off at the main disconnect and lock out to secure against unwanted or accidental switching on Warning of hot surface r Do not touch surface danger of burning Wear long sleeve garments not synthetics such as polyester and protec tive gloves Beware machine starts automatically Machine can start automatically or by remote start command Before opening the machine switch off at the main disconnect and lock out to secure against unwanted or accidental switching on Beware of rotating belt drive Do not open the casing while the machine is switched on Before opening the machine switch off at the main disconnect and lock out WARNING to secure against unwanted or accidental switching on 3 12 3 7 3 7 1 3 7 2 3 8 KAESER Emergencies Fire supression Suitable extinguishing media e foam e powder e carbon dioxide sandor earth Unsuitable or unsafe extinguishing media e powerful water jet Cooling oil Skin contact
90. upply cable section and fuse rating adequate 5 All electrical connections checked for tightness 6 Shut off valve fitted to compressed air outlet 8 gt Belt tension checked Is there sufficient cooling oil in the separator tank re Required quantity of cooling oil poured into the inlet port r Are the operators full conversant with safety regulations gt Maintenance canopy closed Tab 15 Installation conditions checklist 7 re Connection made to compressed air system with hose or 5 axial compensator Setting the overload protection cut out Compressor motor three phase The phase current is fed via the overload protection cut out This phase current is 0 58 times the rated machine current see nameplate in the control cabinet Setting The standard setting is made at the factory To prevent the overload protection cutout from being triggered by voltage fluctuations tem perature influences or component tolerances the setting can be higher than the arithmeti cal phase current Compressor motor single phase The motor supply current is fed via the overload protection cutout see the nameplate in the control cabinet for rated motor current Setting The standard setting is made at the factory To prevent the overload protection cutout from being triggered by voltage fluctuations tem perature influences or component tolerances the setting can be higher than the rated mo tor cur
91. ut off valve 11 to allow oil to drain out and close immediately when air begins to escape Draining the from the cooler ae 15 Changing the cooling cooler 2 Oil drain plug 10 45 KAESER COMPRESSORS Maintenance Have an oil container ready Slowly unscrew the drain plug 2 to allow to drain completely and residual air to escape r Check that the oil separator tank pressure gauge reads zero Tighten drain plug 2 Filling with cooling oil rr Slowly open filler plug 4 Fig 14 re Fill with oil Check the plug and gasket for damage and re insert the plug Start the machine and carry out a test run Open the shut off valve 10 in the venting line Close and lock the maintenance canopy Open the user s shut off valve between the machine and the compressed air system Switch on at the main disconnect Switch the machine on Y y yy yyy After about ten minutes switch the machine off check the oil level and top up again if necessary re Carry out a visual check for leaks 10 11 Oil Filter Maintenance Equipment Replacement part Oil catchment container Pre condition Machine switched off Main disconnect locked out Machine fully vented no pressure Pressure gauge on the oil separator tank indicates zero Danger of burns from hot components and CAUTION Wear long sleeved clothing and gloves t Work
92. y cycle and ambient conditions are important criteria for the number and length of the change intervals KAESER LUBRICANTS SIGMA DESCRIPTION MAXIMUM RECOMMENDED LUBRICANT CHANGE INTERVAL First Oil Change Subsequent Oil Change ISO 46 Semi Synthetic Lubricant 2000 Hours 3000 Hours ISO 46 Synthetic Lubricant 6000 Hours 8000 Hours Cool to moderate ambient temperatures low humidity high duty cycle Tab 17 Oil change intervals lubricants SPECIALTY KAESER LUBRICANTS Refer to product information to determine suitability SIGMA DESCRIPTION MAXIMUM RECOMMENDED LUBRICANT CHANGE INTERVAL First Oil Change Subsequent Oil Change ISO 68 Synthetic Lubricant 6000 Hours 8000 Hours ISO 46 Food Grade Synthetic Fluid 2000 Hours 3000 Hours Cool to moderate ambient temperatures low humidity high duty cycle Tab 18 Oil change intervals speciality lubricants 10 2 3 Regular Service Work e I Only authorized KAESER service agents should carry out service work When operating conditions are unfavorable e g dusty atmosphere or when the equipment is heavily utilised service work must be carried out at shorter intervals Interval Service work up to 12000 hours Check valves Up to 12000 hours Change the drive motor bearings at the latest every 3 years Up to 36000 hours Change the hose lines at the latest every 8 years Tab 19 Regular service work intervals 10 36 KAESER COMPRESSO

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