Manual Kaeser PDF

DESALINATED WATER SUPPLY FOR
SPENCE GROWTH OPTIONS PROJECT
IOM MANUAL
COMPRESSORS MODEL ASK40SFC – DESAL PLANT Air System
COMPRESSORS MODEL ASK34SFC - DAF Air System
COMPRESSORS MODEL SK25SFC – INTAKE Air System
Doc. Nº: SGO-NPIW-EXE-GNR-GFE-01038

Revision: B Date: 21/01/2020
Equipment Supplied by
DESALINATED WATER SUPPLY FOR
SPENCE GROWTH OPTIONS PROJECT
IOM MANUAL Doc. SGO-NPIW-EXE-GNR-MFE-01038-A

Rev. B Date: 21-01-2020
COMPRESSORS MODEL SK25SFC – INTAKE Air System Page 2 of 270
CHANGE LOG
SECTION / PARAGRAPH
REV. DATE AFFECTED REASONS FOR CHANGE
____ _______ ______________________ _____________________________
A 27/08/2019 FOR REVIEW FOR REVIEW
B 21/01/2020 FINAL DOCUMENT FOR FOR APPROVAL

APPROVAL
TEDAGUA Doc. No.: SGO-NPIW-EXE-GNR-MFE-01038-A

IOM MANUAL
B 21/01/2020 FINAL DOCUMENT FOR APPROVAL S.CARVAJAL J.VASQUEZ J.VASQUEZ
A 27/08/2019 Issue for Review S.CARVAJAL J.VASQUEZ J.VASQUEZ
Rev. Date Description Prepared Checked Approved

Operating Manual
Rotary screw compressor
ASK SFC
901748 14 E

Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com
Original instructions
/KKW/SASK 2.24 en SBA-SCHRAUBEN-SFC-SC2
/KKW/SSC 2.09
20190708 132232
Contents
1 Regarding this document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Mass ................................................................................................................................. 5
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 6
2.8 Flow rate (constant delivery volume relative to intake conditions) ................................... 7
2.8.1 Rated voltage 400 V / 3 / 50 Hz .......................................................................... 8
2.9 Cooling oil recommendation ............................................................................................. 11
2.10 Cooling oil charge quantity ............................................................................................... 13
2.11 Motors and power ............................................................................................................ 13
2.11.1 Compressor drive motor ..................................................................................... 13
2.11.2 Fan motor ........................................................................................................... 13
2.12 Noise emission [dB(A)] ..................................................................................................... 14
2.13 Electrical connection ........................................................................................................ 14
2.14 Power supply specifications ............................................................................................. 15
2.14.1 Earthed conductor specification .......................................................................... 15
2.14.2 Mains frequency: 50 Hz ...................................................................................... 15
2.15 Heat recovery ................................................................................................................... 16
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 20
3.2 Specified use .................................................................................................................... 20
3.3 Improper use .................................................................................................................... 20
3.4 User's responsibilities ....................................................................................................... 20
3.4.1 Observe statutory and universally accepted regulations .................................... 20
3.4.2 Determining personnel ........................................................................................ 21
3.4.3 Complying with Inspection Schedules and Accident Prevention Regulations .... 21
3.5 Dangers ............................................................................................................................ 22
3.5.1 Safely dealing with sources of danger ................................................................ 22
3.5.2 Safe machine operation ...................................................................................... 24
3.5.3 Organisational Measures .................................................................................... 26
3.5.4 Danger Areas ...................................................................................................... 26
3.6 Safety devices .................................................................................................................. 27
3.7 Service life of safety functions .......................................................................................... 27
3.8 Safety signs ...................................................................................................................... 28
3.9 Emergency situations ....................................................................................................... 29
3.9.1 Correct fire fighting ............................................................................................. 29
3.9.2 Treating injuries from handling cooling oil .......................................................... 30
3.10 Warranty ........................................................................................................................... 30
3.11 Environment protection .................................................................................................... 30
Operating Manual Rotary screw compressor

901748 14 E ASK SFC i
Contents
4 Design and Function

4.1 Housing ............................................................................................................................ 32
4.2 Machine function .............................................................................................................. 33
4.2.1 Frequency Converter .......................................................................................... 33
4.2.2 Safety devices .................................................................................................... 34
4.2.3 Floating relay contacts ........................................................................................ 34
4.3 Operating panel SIGMA CONTROL 2 ............................................................................. 34
4.4 Operating modes and control modes ............................................................................... 37
4.4.1 Machine operating modes .................................................................................. 37
4.4.2 Control modes .................................................................................................... 38
4.4.3 Variable speed drive with frequency converter (SFC) ........................................ 39
4.5 Options ............................................................................................................................. 39
4.5.1 SIGMA CONTROL 2 controller: Connection to control technology .................... 39
4.5.2 Machine mountings ............................................................................................. 40
4.5.3 Heat recovery ..................................................................................................... 40
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 41
5.2 Installation conditions ....................................................................................................... 41
5.2.1 Determining location and clearances .................................................................. 41
5.2.2 Ensuring the machine room ventilation ............................................................... 42
5.2.3 Exhaust duct design ........................................................................................... 43
5.3 Operating the machine in a compressed air network ....................................................... 43
6 Installation
6.1 Ensuring safety ................................................................................................................ 44
6.2 Reporting Transport Damage ........................................................................................... 45
6.3 Connecting the machine with the compressed air network .............................................. 45
6.4 Connecting the external pressure transducer .................................................................. 46
6.5 Connecting the machine to the power supply .................................................................. 46
6.6 Options ............................................................................................................................. 47
6.6.1 Anchoring the machine ....................................................................................... 47
6.6.2 Connecting the heat recovery system ................................................................ 47
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 49
7.2 Instructions to be observed before commissioning .......................................................... 50
7.3 Checking installation and operating conditions ................................................................ 50
7.4 Commissioning the Frequency Converter ........................................................................ 51
7.5 Pouring cooling oil into the airend .................................................................................... 51
7.6 Setting the motor overload protection switch ................................................................... 52
7.7 Starting the machine for the first time .............................................................................. 52
7.8 Checking the direction of rotation ..................................................................................... 53
7.9 Setting the set point pressure .......................................................................................... 53
7.10 Setting the display language ............................................................................................ 53
8 Operation
8.1 Switching on and off ......................................................................................................... 55
8.1.1 Switching on ....................................................................................................... 55
8.1.2 Switching off ....................................................................................................... 55
8.2 Switching off in an emergency and switching on again .................................................... 56
8.3 Using the remote control for switching on and off ............................................................ 56
8.4 Using the timer for switching on and off ........................................................................... 57
8.5 Interpreting operation messages ...................................................................................... 58
8.6 Acknowledging alarm and warning messages ................................................................. 58

ii ASK SFC 901748 14 E
Contents
9 Fault Recognition and Rectification

9.2 Other faults ....................................................................................................................... 60
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 62
10.2 Following the maintenance plan ....................................................................................... 63
10.2.1 Logging maintenance work ................................................................................. 63
10.2.2 Resetting maintenance interval counters ............................................................ 63
10.2.3 Regular maintenance tasks ................................................................................ 64
10.2.4 Cooling oil Change interval ................................................................................. 65
10.2.5 Regular service tasks ......................................................................................... 65
10.3 Cooler: Cleaning or Renewing the Filter Mats ................................................................. 66
10.4 Control cabinet: Clean or renew the filter mat .................................................................. 67
10.5 Cooler maintenance ......................................................................................................... 67
10.6 Maintain the heat recovery system .................................................................................. 69
10.7 Air Filter Maintenance ...................................................................................................... 69
10.8 Motor maintenance .......................................................................................................... 70
10.9 Drive belt maintenance .................................................................................................... 70
10.10 Testing the pressure relief valve ...................................................................................... 71
10.11 Check the safety shut-down due to excessive airend discharge temperature. ................ 72
10.12 Check the EMERGENCY STOP control device ............................................................... 72
10.13 Checking the cooling oil level ........................................................................................... 73
10.14 Venting the machine (de-pressurising) ............................................................................ 73
10.15 Replenish cooling oil ........................................................................................................ 75
10.15.1 Venting the machine (de-pressurising) ............................................................... 76
10.15.2 Topping up with cooling oil and trial run ............................................................. 77
10.16 Changing the cooling oil ................................................................................................... 78
10.17 Changing the oil filter ....................................................................................................... 83
10.18 Changing the oil separator cartridge ................................................................................ 84
10.19 Documenting maintenance and service work .................................................................. 87
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 88
11.2 Ordering consumable parts and operating fluids/materials .............................................. 88
11.3 KAESER AIR SERVICE ................................................................................................... 88
11.4 Replacement parts for service and repair ........................................................................ 89
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 92
12.1.1 Temporary de-commissioning ............................................................................ 92
12.1.2 Long-term de-commissioning ............................................................................. 92
12.2 Packing ............................................................................................................................ 93
12.3 Storage ............................................................................................................................. 93
12.4 Transport .......................................................................................................................... 93
12.4.1 Safety .................................................................................................................. 93
12.4.2 Transport with a forklift truck ............................................................................... 93
12.4.3 Transport with a hoist ......................................................................................... 94
12.5 Disposal ........................................................................................................................... 96
12.5.1 Battery disposal in accordance with local environmental regulations. ................ 96
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 97
13.2 Dimensional drawing ........................................................................................................ 103
13.3 Electrical Diagram ............................................................................................................ 106

901748 14 E ASK SFC iii
Contents

iv ASK SFC 901748 14 E
List of Illustrations
Fig. 1 Maximum relative humidity of intake air ..................................................................................... 6

Fig. 2 Flow rate and regulating range ................................................................................................... 8
Fig. 3 Location of safety signs .............................................................................................................. 28
Fig. 4 Housing overview ....................................................................................................................... 32
Fig. 5 Machine layout ........................................................................................................................... 33
Fig. 6 Keys – overview ......................................................................................................................... 34
Fig. 7 Indicators – overview .................................................................................................................. 35
Fig. 8 RFID reader ................................................................................................................................ 36
Fig. 9 Machine mountings .................................................................................................................... 40
Fig. 10 Function of the heat recovery ..................................................................................................... 40
Fig. 11 Recommended machine placement and dimensions [mm] ........................................................ 42
Fig. 12 Compressed air pipework ........................................................................................................... 45
Fig. 13 Connecting the heat recovery system ........................................................................................ 48
Fig. 14 Airend filling port ......................................................................................................................... 52
Fig. 15 Switching on and off ................................................................................................................... 55
Fig. 16 Switching off in an emergency ................................................................................................... 56
Fig. 17 Using the remote control for switching on and off ...................................................................... 57
Fig. 18 Using the timer for switching on and off ..................................................................................... 58
Fig. 19 Acknowledging messages .......................................................................................................... 59
Fig. 20 Filter mat for the air and oil cooler .............................................................................................. 66
Fig. 21 Switching cabinet ventilation ...................................................................................................... 67
Fig. 23 Air filter maintenance .................................................................................................................. 69
Fig. 24 Drive belt maintenance ............................................................................................................... 70
Fig. 25 Check the EMERGENCY STOP control device ......................................................................... 72
Fig. 26 Checking the cooling oil level ..................................................................................................... 73
Fig. 27 Venting the machine ................................................................................................................... 74
Fig. 28 Replenish cooling oil .................................................................................................................. 76
Fig. 29 Changing the cooling oil, pressuring the oil separator tank ........................................................ 78
Fig. 30 Changing the cooling oil Oil separator tank ................................................................................ 79
Fig. 31 Changing the cooling oil Oil cooler ............................................................................................. 80
Fig. 32 Changing the cooling oil Airend .................................................................................................. 81
Fig. 33 Changing the cooling oil Heat recovery ...................................................................................... 82
Fig. 34 Changing the cooling oil Filling with cooling oil .......................................................................... 82
Fig. 35 Changing the oil filter .................................................................................................................. 83
Fig. 36 Changing the oil separator cartridge .......................................................................................... 85
Fig. 37 Transporting with a forklift truck ................................................................................................. 94
Fig. 38 Transporting with a crane ........................................................................................................... 95
Fig. 39 Battery labelling .......................................................................................................................... 96

901748 14 E ASK SFC v

vi ASK SFC 901748 14 E
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Mass ........................................................................................................................................... 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 8 Overview Ventilation (50Hz) ....................................................................................................... 6
Tab. 10 Pressure relief valve activating pressure (50 Hz) ....................................................................... 7
Tab. 11 Pressure relief valve activating pressure (60Hz) ........................................................................ 7
Tab. 12 Flow rate 400 V / 8.0 bar ............................................................................................................ 8
Tab. 13 Flow rate 400 V / 11.0 bar .......................................................................................................... 8
Tab. 21 Cooling oil recommendation ....................................................................................................... 11
Tab. 22 Cooling oil recommendation (food processing) .......................................................................... 12
Tab. 23 Cooling oil recommendation (machines for snow cannons) ....................................................... 12
Tab. 24 Cooling oil charge quantity ........................................................................................................ 13
Tab. 25 Cooling oil charge (Option W2) .................................................................................................. 13
Tab. 26 Cooling oil charge (option W3) ................................................................................................... 13
Tab. 27 Compressor drive motor ............................................................................................................. 13
Tab. 28 Fan motor (50Hz) ....................................................................................................................... 13
Tab. 29 Fan motor (60Hz) ....................................................................................................................... 14
Tab. 30 Noise emission [dB(A)] ............................................................................................................... 14
Tab. 31 Supply details 400V / 3 / 50Hz ................................................................................................... 15
Tab. 35 Heat recovery: Individual design data ........................................................................................ 17
Tab. 36 Specification: Heat exchanger (Option W2/W3) ......................................................................... 17
Tab. 37 Quality of the heat receiving medium ......................................................................................... 18
Tab. 38 Heat capacity (Option W2/W3) ................................................................................................... 18
Tab. 39 Flow rate / pressure drop (option W2) ........................................................................................ 18
Tab. 40 Flow rate / pressure drop (option W3) ........................................................................................ 18
Tab. 41 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 22
Tab. 42 Danger Areas ............................................................................................................................. 27
Tab. 43 Category and Performance Level ............................................................................................... 27
Tab. 44 Safety signs ................................................................................................................................ 28
Tab. 45 Keys ........................................................................................................................................... 34
Tab. 46 LEDs ........................................................................................................................................... 36
Tab. 47 RFID reader ................................................................................................................................ 37
Tab. 48 Energy-efficient control modes ................................................................................................... 38
Tab. 49 Components ............................................................................................................................... 39
Tab. 50 Re-commissioning after storage/standstill .................................................................................. 50
Tab. 51 Installation conditions checklist .................................................................................................. 50
Tab. 52 Machine identification ................................................................................................................. 57
Tab. 53 Remote control identification ...................................................................................................... 57

901748 14 E ASK SFC vii
List of Tables
Tab. 55 Other faults and remedies .......................................................................................................... 60

Tab. 56 Advise others that the machine is being serviced. ..................................................................... 62
Tab. 57 Regular maintenance tasks ........................................................................................................ 64
Tab. 58 Cooling oil Change intervals ....................................................................................................... 65
Tab. 59 Regular service tasks ................................................................................................................. 66
Tab. 60 Logged maintenance tasks ........................................................................................................ 87
Tab. 61 Consumable parts ...................................................................................................................... 88

viii ASK SFC 901748 14 E
1.1 Using this document

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

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

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

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warnings indicate risks potentially resulting in personal injury, if the measures specified are not
taken.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal word Meaning Consequences of non-compliance
DANGER Warns of an imminent danger Will very likely result in death or severe injury
WARNING Warns of a potentially imminent dan‐ May result in death or severe injury
ger
CAUTION Warns of a potentially dangerous sit‐ May result in a moderate physical injury
uation
Tab. 1 Danger levels and their definition (personal injury)

901748 14 E ASK SFC 1
Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐
tions.
Example:
DANGER
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The word "DANGER" indicates that death or severe injury can very likely result from ignoring
the warning.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The word "WARNING" indicates that death or severe injury may result from ignoring the warn‐
ing.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Damage warnings have only one danger level, identified with this signal word:
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alert notes and their symbols

This symbol indicates particular important information.

2 ASK SFC 901748 14 E
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
Option H1 ➤ This symbol is placed by lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with bolt-down machine feet). Option codes used in this
operating manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.

901748 14 E ASK SFC 3
2.1 Nameplate
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine at one of these positions:
■ Above the cooler
■ On the rear side of the machine
➤ Enter here the nameplate data as a reference:
Characteristic Value
Material No.
Serial No.
Ambient temperature
Rated power
Maximum working pressure PS
Rated motor speed
Phases
Voltage
Full load current
Electrical diagram
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options. The options for this machine are shown near the
nameplate.
➤ Enter options here as a reference:
Option Option code Provided?

SIGMA CONTROL 2 C3 ✓
(Prepared for connection to control centre)
IT 3-phase supply C35 —
SIGMA CONTROL 2 C48 —
(Connection to control technology not provided)
Bolt-down machine mounts H1
Air-cooling K1 ✓
Transformer power supply for refrigeration dryer T2 —
Heat recovery ΔT=25 K W2
Provided: ✓
Not available: —

4 ASK SFC 901748 14 E
2.3 Mass
Option Option code Provided?

Heat recovery ΔT=55 K W3
Provided: ✓
Not available: —
Tab. 4 Options
2.3 Mass
The values shown are maximum values. Actual mass of individual machines are dependent on
equipment fitted.
ASK 28 ASK 34 ASK 40

Mass [kg] — 530 550
Tab. 5 Mass
2.4 Temperature
Minimum cut-in tempera‐ — 3 3
ture [°C]
Typical airend discharge — 65 – 100 65 – 100
temperature during oper‐
ation [°C]
Maximum airend dis‐ — 110 110
charge temperature (au‐
tomatic safety shut-down)
[°C]
Tab. 6 Temperature
2.5 Ambient conditions

Maximum elevation amsl — 1000 1000
[m]
Permissible ambient tem‐ — 3 – 45 3 – 45
perature [°C]
Cooling air temperature — 3 – 45 3 – 45
[°C]
Intake air temperature — 3 – 45 3 – 45
[°C]
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions

901748 14 E ASK SFC 5
2.6 Ventilation
Fig. 1 Maximum relative humidity of intake air

T Intake air temperature [°C]
H Maximum relative humidity of intake air [%]
2.6 Ventilation
The values given are minimum guide values.
Mains frequency: 50 Hz

Inlet aperture Z see fig‐ — 0.6 0.7
ure 11 [m2]
Forced ventilation with — 8000 10000
exhaust fan:
Flow rate [m3/h] at 100
Pa
Tab. 8 Overview Ventilation (50Hz)

Inlet aperture Z see fig‐ — 0.6 0.7
ure 11 [m2]
Forced ventilation with — 8000 10000
exhaust fan:
Pa
2.7 Pressure
See nameplate for maximum working pressure

6 ASK SFC 901748 14 E
2.8 Flow rate (constant delivery volume relative to intake conditions)
Activating pressure [bar] of the relief valve at 50 Hz mains frequency:
Maximum working over‐ ASK 28 ASK 34 ASK 40

pressure [bar]
8.0 — 10 10
11.0 — 13 13
15.0 —* 16* 16*
* China: 15.9
Tab. 10 Pressure relief valve activating pressure (50 Hz)
Maximum working over‐ ASK 28 ASK 34 ASK 40

pressure [bar]
8.5 — 10 10
11.0 — 13 13
15.0 — 16 16
Tab. 11 Pressure relief valve activating pressure (60Hz)

Fig. 2 indicates the regulating range of the flow rate 1 , dependant on all current pressure condi‐
tions at the compressed air outlet of the machine (local network pressure pNloc).

901748 14 E ASK SFC 7
Fig. 2 Flow rate and regulating range

1 Q 6 pAmax
Flow rate Maximum selectable set-point pressure
2 Qmax 7 p
Maximum flow rate (pNloc) Pressure
3 Qmin 8 Qmin (p)
Minimum flow rate (pNloc) Minimum flow rate
4 pAmin 9 Qmax (p)
Minimum selectable system set-point Maximum flow rate
pressure (parameter-dependent)
5 pNloc
Local network pressure at the compressed
air outlet
2.8.1 Rated voltage 400 V / 3 / 50 Hz

Flow rate Q [m3/min] at maximum working pressure 8.0 bar:
pNloc [bar] ASK 28 ASK 34 ASK 40

Qmin Qmax Qmin Qmax Qmin Qmax
pAmin — — 0.95 4.01 0.95 4.65
6.0 — — 0.95 4.01 0.95 4.54
7.0 — — 0.94 3.7 0.94 4.31
8.0 (pAmax) — — 0.94 3.50 0.94 4.08
Flow rate as per ISO 1217:2009. Annex E
Tab. 12 Flow rate 400 V / 8.0 bar

pAmin — — 0.82 3.37 0.82 3.96
9.0 — — 0.81 3.29 0.81 3.88

8 ASK SFC 901748 14 E

10.0 — — 0.80 3.14 0.80 3.71
11.0 (pAmax) — — 0.79 2.89 0.79 3.54

pAmin — — 0.90 2.82 0.90 3.31
12.0 — — 0.90 2.82 0.90 3.31
13.0 — — 0.88 2.70 0.88 3.17
14.0 — — 0.86 2.57 0.86 3.04
15.0 (pAmax) — — 0.84 2.45 0.84 2.90


pAmin — — 0.95 3.80 0.95 4.44
6.0 — — 0.95 3.70 0.95 4.33
7.5 — — 0.94 3.40 0.94 4.01
8.5 (pAmax) — — 0.94 3.22 0.94 3.79

pAmin — — 0.79 3.11 0.79 3.67
9.0 — — 0.79 3.11 0.79 3.67
10.0 — — 0.78 2.96 0.78 3.50

901748 14 E ASK SFC 9

11.0 (pAmax) — — 0.77 2.81 0.77 3.33

pAmin — — 0.88 2.64 0.88 3.14
12.0 — — 0.88 2.64 0.88 3.14
13.0 — — 0.86 2.51 0.86 3.00
14.0 — — 0.84 2.39 0.84 2.87
15.0 (pAmax) — — 0.82 2.26 0.82 2.73


pAmin — — 0.95 4.01 0.95 4.44
6.0 — — 0.95 3.91 0.95 4.33
7.5 — — 0.94 3.60 0.94 4.01
8.5 (pAmax) — — 0.94 3.4 0.94 3.79

pAmin — — 0.79 3.29 0.79 3.67
9.0 — — 0.79 3.29 0.79 3.67
10.0 — — 0.78 3.13 0.78 3.50
11.0 (pAmax) — — 0.77 2.98 0.77 3.33

10 ASK SFC 901748 14 E
2.9 Cooling oil recommendation

pAmin — — 0.88 2.74 0.88 3.14
12.0 — — 0.88 2.74 0.88 3.14
13.0 — — 0.86 2.63 0.86 3.00
14.0 — — 0.84 2.52 0.84 2.87
15.0 (pAmax) — — 0.82 2.41 0.82 2.73

A sticker showing the type of oil used is located near the oil separator tank filler.
For information on ordering cooling oil, please see chapter 11.
Cooling oils for general applications
SIGMA FLUID
MOL S-460 S-570
Description Mineral oil Synthetic oil Synthetic oil
Application Standard oil for all appli‐ Standard oil for all applica‐ Special oil for ambient con‐
cations except in connec‐ tions except in connection ditions with high tempera‐
tion with processing of with processing of food‐ tures and humidity.
foodstuffs. stuffs. Standard oil for all applica‐
Particularly suitable for Particularly suitable for ma‐ tions except in connection
machines with a low duty chines with a high duty cy‐ with foodstuffs.
cycle. cle. Particularly suitable for ma‐
Not suitable for East and chines with a high duty cy‐
South East Asia. cle.
Viscosity at 46 mm2/s 46 mm2/s 53 mm2/s
40°°C (ASTM D445) (ASTM D445) (ASTM D445)
Viscosity at 6.9 mm2/s 7.2 mm2/s 8.0 mm2/s
100 °C (ASTM D445) (ASTM D445) (ASTM D445)
Flash point 230 °C 251 °C 258 °C
(ASTM D92) (ASTM D92) (ASTM D92)
Density at 0.868 g/cm3 0.860 g/cm3 0.869 g/cm3
Pour point: −30 °C −27 °C −54 °C
Tab. 21 Cooling oil recommendation

901748 14 E ASK SFC 11
Cooling oils for applications in food processing
SIGMA FLUID
FG-460 FG-680
Description Synthetic oil Synthetic oil
Application Specifically for machines in applica‐ Special oil for ambient conditions with high
tions where the compressed air may temperatures and humidity.
come into contact with foodstuff. Specifically for machines in applications
where the compressed air may come into
contact with foodstuff.
Approval USDA H1, NSF USDA H1, NSF
Approved for applications where Approved for applications where contact
contact with foodstuffs may sporadi‐ with foodstuffs may sporadically or inci‐
cally or incidentally be possible. dentally be possible.
Viscosity at 40° 46 mm2/s (ASTM D445) 68 mm2/s (ASTM D445)

°C
Viscosity at 8.0 mm2/s (ASTM D445) 10.5 mm2/s (ASTM D445)
100 °C
Flash point 246 °C (ASTM D92) 238 °C (ASTM D92)
Density at 0.842 g/cm3 (ASTM D1298) 0.854 g/cm3 (ASTM D1298)
15 °C
Pour point: −39 °C (ASTM D97) −39 °C (ASTM D97)
Tab. 22 Cooling oil recommendation (food processing)
Cooling oils for the operation with snow cannons
SIGMA FLUID
PANOLIN HLP SYNTH 46
Description Saturated synthetic ester with additives (mineral oil free)
Easily biologically degradable as per OECD criteria
Application Specifically designed for machines intended for the operation with snow can‐
nons.
Viscosity at 40°°C 47 mm2/s (ISO 2104)
Viscosity at 8.2 mm2/s (ISO 2104)
100 °C
Flash point 240 °C (ISO 2592)
Density at 15 °C 0.918 g/cm3 (ISO 12185, ISO 3675)
Pour point: -57 °C (ISO 3016)
Tab. 23 Cooling oil recommendation (machines for snow cannons)

12 ASK SFC 901748 14 E
2.10 Cooling oil charge quantity
2.10 Cooling oil charge quantity

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

Fluid volume* [l] — 11 11
Topping up volume [l] — 2 2
(minimum–maximum)
* plus the cooling oil volume of the heat recovery system.
Tab. 24 Cooling oil charge quantity
Option W2/W3 Heat recovery
Option W2 ASK 28 ASK 34 ASK 40

Additional charge vol‐ — 1.2 1.2
ume [l]
Tab. 25 Cooling oil charge (Option W2)
Option W3 ASK 28 ASK 34 ASK 40

Additional charge vol‐ — 1.2 1.2
ume [l]
Tab. 26 Cooling oil charge (option W3)
2.11 Motors and power

2.11.1 Compressor drive motor
Rated power [kW] — 18.5 22.0
Enclosure protection — IP55 IP55
Tab. 27 Compressor drive motor
2.11.2 Fan motor

Mains frequency: *50 Hz

h = operating hours
Tab. 28 Fan motor (50Hz)

901748 14 E ASK SFC 13
2.12 Noise emission [dB(A)]
Mains frequency: *60 Hz

h = operating hours
Tab. 29 Fan motor (60Hz)

Mains frequency ASK 28 ASK 34 ASK 40
50 Hz — 68 70
60 Hz — 70 72
Noise pressure level in operation at maximum gauge working pressure and maximum attainable
speed as per ISO 2151 and the basic standard ISO 9614-2, uncertainty: ±3 dB(A)
Tab. 30 Noise emission [dB(A)]
2.13 Electrical connection

Basic requirements
The machine is designed in accordance with the conditions for an electrical power supply specified
in EN 60204-1 (IEC 60204-1) section 4.3.
If no other conditions are specified by the operator, the thresholds described in this standard must
be adhered to.
It is recommended that the user and the supplier reach an agreement on the basis of EN 60204-1,
Annex B.
For electrical connection of the machine, a symmetric three-phase supply is necessary.
In a symmetrical three phase supply the phase angles and voltages are all the same.
This machine is designed for the operation in an industrial environment with proprietary supply net‐
work separated from the public supply by a transformer or generator.
Incoming line within the switching cabinet to be as short as possible.
If external sensors or communications lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC connections into the switching cabinet.
This machine may only be supplied from an earthed TN or TT three-phase supply in which
the neutral point is earthed.
The connection to an IT three-phase supply or a three-phase supply with one earthed phase
is not permitted.
Further information The wiring diagram in chapter 13.3 contains further details of the power supply connection.

14 ASK SFC 901748 14 E
2.14 Power supply specifications

The following supply cable conductor cross sections and fusing (slow-blow class gG) are selected
according to German DIN VDE 0100 Part 430 (IEC 60364-4-43) and DIN VDE 0298-4:2013-06
standards for these conditions:
■ Multi-core copper conductors with an operating temperature up to 70 °C
■ Cable length <50 m
■ for ambient temperature of 30 °C
■ Wiring type C, without cable contact
■ Current carrying capacity: Table 3 Column 11
(European Harmonisation Directive HD 60364-5-52: 2011)
■ Cable bundling: Table 21
─ Single layer on wall or floor
─ Spacing ≥ outside diameter
➤ For other application conditions, check and determine the supply cross-sections accord‐
ing to DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider.
Other application conditions would include, for example:

■ Higher ambient temperature
■ Other cable installation method
■ Other cable bundling
■ Cable length >50 m
Further information The circuit diagram in chapter 13.3 contains further details of the electric supply connection data.
2.14.1 Earthed conductor specification

Due to the leakage currents caused by the anti-interference capacitors of the frequency converter,
a minimum diameter of 10 mm2 is required for the earthed conductor (see EN 60204-1).
Use one of the following options, if the earthed conductor for the supply line is smaller than
10 mm2:
■ Multi-core conductor including earthed conductor with a minimum diameter of 10 mm2,
■ A minimum diameter of 10 mm2 for the earth conductor alone,
■ a second earth conductor with the same diameter as the supply line,
■ automatic deactivation of the supply as soon as the earth conductor is interrupted.
2.14.2 Mains frequency: 50 Hz

Rated voltage: 400V / 3 / 50Hz

Main fuse [A] — 63 80
Supply cable [mm2] — 4x16 4x25
Current consumption [A] — 55 72
Tab. 31 Supply details 400V / 3 / 50Hz

901748 14 E ASK SFC 15
2.15 Heat recovery



Main fuse [A] — — —
Supply cable [mm2] — — —
Current consumption [A] — — —

2.15 Option W2/W3

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

■ Fluctuating condensate flow
■ Working pressure
■ Inlet conditions
■ Ambient conditions
■ Machine settings
Water is generally the heat-receiving medium. The water must meet the quality specified below in
order not to damage the heat exchanger.

16 ASK SFC 901748 14 E
2.15 Heat recovery
The specified flow rate relates to the maximum available heat capacity.
➤ If required, enter your individual values in the prepared table.
➤ Consult KAESER SERVICE if you wish to use a different heat-receiving medium.
The primary side of the heat exchanger is connected to the cooling oil circuit of the machine.
The specifications refer to the secondary side of the heat exchanger.
Individual design data
My value
Heating from [°C]
Heating to [°C]
Temperature difference
(ΔT) [K]
Maximum available heat
output [kW]
(relative to ___ bar work‐
ing pressure)
Flow rate [m3/h]
Pressure drop [bar]
Tab. 35 Heat recovery: Individual design data
Component sprecification:
Feature Value
Material 1.4401
Braze Copper (Cu)
Max. working pres‐ 10
sure [bar]
Minimum permissible in‐ 5
let temperature [°C]
Max. permissible inlet 45
temperature* [°C]
Continuously possible 70
outlet temperature [°C]
Maximum permissible 100
outlet temperature [°C]
(Component limit value)
Maximum permissible 8.7
flow rate [m3/h]
Unsuitable cooling media Salt water
Consult KAESER on the suitability of water.
* Consult KAESER about higher values.
Tab. 36 Specification: Heat exchanger (Option W2/W3)

901748 14 E ASK SFC 17
2.15 Heat recovery
Quality of the heat receiving medium
Characteristics/content Value
pH value 7.5 – 9.0
Hardness [°dH] 0 – 20
Carbonate hardness* [°dH] <20
Chlorides (Cl) [mg/l] <100
Iron (Fe), dissolved [mg/l] <0.5
Sulphate (SO4) [mg/l] <100
HCO3/SO4 ratio >1
Electrical conductivity [µS/cm] 10 – 800
Ammonia (NH4+) [mg/l] <1
Manganese (Mn), dissolved [mg/l] <0.1
Glycol [%] 20–40
Solids (particle size) [mm] <0.1
Bacterial count [CFU*/ml] 10,000
Suspended solids [ppm] <20
(portion of undissolved matter)
* CFU: colony-forming units
Tab. 37 Quality of the heat receiving medium
Heat capacity
Maximum heat capacity ASK 28 ASK 34 ASK 40

available
[kW] — 16.9 19.8
[MJ/h] — 61 71
[kcal/h] — 14500 17000
Tab. 38 Heat capacity (Option W2/W3)
Option W2 Flow rate for heating from 45 °C to 70 °C (equates to ΔT=25K)

Flow rate [m3/h] — 0.58 0.68
Pressure drop [bar] — 0.15 0.15
Tab. 39 Flow rate / pressure drop (option W2)
Option W3 Flow rate for heating from 15 °C to 70 °C (equates to ΔT=55K)

Flow rate [m3/h] — 0.26 0.31

18 ASK SFC 901748 14 E
2.15 Heat recovery

Pressure drop [bar] — 0.10 0.10
Tab. 40 Flow rate / pressure drop (option W3)

901748 14 E ASK SFC 19
3.1 Basic instructions

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ impairments to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the operating manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
3.2 Specified use

The machine is intended solely for generating compressed air for industrial use. Any other use is
considered incorrect. The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
➤ Comply with the instructions in this operating manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated.
➤ Do not use compressed air for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated.
3.3 Improper use

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

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

20 ASK SFC 901748 14 E
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.
3.4.2 Determining personnel

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

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

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

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

901748 14 E ASK SFC 21
3.5 Dangers
➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in § 16:
Inspection Inspection interval Inspecting authority

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

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

22 ASK SFC 901748 14 E
3.5 Dangers
➤ De-pressurise all pressurised components and enclosures.

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

901748 14 E ASK SFC 23
3.5 Dangers
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

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

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

■ Safety work wear
■ Protective gloves

24 ASK SFC 901748 14 E
3.5 Dangers
■ Safety boots
■ Eye protection
■ Ear protection
Transport
The mass and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Assembly
➤ Use only electrical cables that are suitable and approved for the surroundings and electrical
loads applied.
➤ Never dismantle compressed air pipes until they are fully vented.
➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Installation
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 2014/34/EC "Equipment and Protective Sys‐
tems intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance: explosive or chemically instable gases and vapours,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in the warm exhaust air flow from other machines.

901748 14 E ASK SFC 25
3.5 Dangers
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
➤ Check that there is no voltage on potential-free contacts.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Carry out regular inspections:
for visible damages,
of safety installations,
of the EMERGENCY STOP command device,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
De-commissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organisational Measures

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

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

26 ASK SFC 901748 14 E
3.6 Safety devices
Activity Danger area Authorised personnel

Transport Within a 3 m radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 1 m radius of the machine and its sup‐
ply cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Tab. 42 Danger Areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4, section 4.2.2.
3.7 Service life of safety functions

Pursuant to ISO 13849-1:2015, Category and Performance Level (PL) of the machine's safety
functions have been analysed and assessed:
Safety function Category Performance Level
Safety shut-down due to excessive airend discharge 2; 3 b
temperature
EMERGENCY STOP device 1; 3 c
Tab. 43 Category and Performance Level
The safety-relevant components of the safety functions are designed for a working life of 20 years.
The working life starts with the commissioning, and is not extended by times during which the ma‐
chine was not in use.
The following components are affected:

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

901748 14 E ASK SFC 27
3.8 Safety signs
3.8 Safety signs

The illustration shows the position of the safety signs on the machine. The table lists the various
safety signs used and their meanings.
Fig. 3 Location of safety signs
Item Sign Meaning

1 Danger of fatal injury from electric shock!
Switch off and lock out the power supply disconnecting device and verify the
absence of any voltage.
2 Hot surface!
Risk of burns caused by contact with hot components!
➤ Do not touch the surface.
➤ Wear long-sleeved garments (no synthetics such as polyester) and protective
gloves.
3 Risk of serious injuries (to the hands, in particular) or even severing of extremities
from rotating components!
➤ Operate the machine only with closed safety guards, access doors and panels.
➤ Switch off and lock out the mains isolating device and secure against uninten‐
tional reactivation.
4 Personal injury or damage to the machine due to incorrect operation!
➤ Read and understand the operating manual and all safety signs before switch‐
ing on this machine.
Risk of injury caused by an automatic machine start!
➤ Switch off and lock out the mains isolating device and secure against uninten‐
tional reactivation.

28 ASK SFC 901748 14 E
3.9 Emergency situations
Item Sign Meaning

5 Risk of fatal injury when dismantling valves (spring-loaded or under pressure)!
➤ Do not open or dismantle valves.
➤ Call an authorised Service Technician in the event of a fault.
6 Serious injury, particularly to the eyes, from foreign objects ejected from rotating
components.
➤ Do not allow anything to fall through the ventilation grille.
➤ Do not work above the machine if it is switched on.
13 Danger to life due to high earth conductor current!
➤ Ensure that the earth conductor is sufficiently dimensioned!
➤ Before starting work on the frequency converter or intermediate circuit capaci‐
tors, wait for, at least, 5 minutes.
Tab. 44 Safety signs

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

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water

901748 14 E ASK SFC 29
3.10 Warranty
3.9.2 Treating injuries from handling cooling oil

Eye contact:
Cooling oil can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.
Skin contact:
Cooling oil may irritate after prolonged contact.

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

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

➤ Do not induce vomiting.
➤ Seek medical aid.
3.10 Warranty
This operating manual does not contain any independent warranty commitment. Our general terms
and conditions apply with regard to warranty.
A condition of our warranty is that the machine is used solely for the purpose for which it is inten‐
ded and under the conditions specified.
Due to the multitude of applications for which the machine is suitable, the user is obliged to deter‐
mine its suitability for his specific application.
Furthermore, we do not assume any warranty obligation for damages caused by:
■ the use of unsuitable parts or operating materials,
■ arbitary modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.11 Environment protection

The operation of this machine may cause dangers for the environment.
➤ Do not allow cooling oil to escape to the environment or into the sewage system.

30 ASK SFC 901748 14 E
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
ment protection regulations.
➤ Observe national regulations.
This applies particularly to parts contaminated with compressor cooling oil.

901748 14 E ASK SFC 31
4.1 Housing

4.1 Housing
Fig. 4 Housing overview

1 Control cabinet door 4 Sight glass: Cooling oil level indicator
2 Latch 5 Sight glass: V-belt tension
3 Access door
When closed, the enclosure serves various functions:

■ Sound insulation
■ Protection against contact with components
■ Cooling air flow
The enclosure is not suitable for the following uses:

■ Walking on, standing on or sitting on the machine.
■ Loads of any kind should not be placed or stored on the machine.
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
The latches should be opened using the supplied key.

32 ASK SFC 901748 14 E
4.2 Machine function
Fig. 5 Machine layout

1 Inlet valve 6 Control cabinet
2 Minimum pressure/check valve 7 Oil separator tank
3 Compressor motor 8 Air filter
4 Oil filter 9 Oil/air cooler
5 Airend
Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure with‐
in the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve
maintains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pres‐
sure / check valve 2 into the air cooler 9 . The minimum pressure / check valve ensures that there
is always a minimum internal pressure sufficient to maintain cooling oil circulation in the machine.
The aftercooler brings down the compressed air temperature to 5K to 10K above ambient. Most of
the moisture carried in the air is removed in the aftercooler.
4.2.1 Frequency Converter

The converter varies the speed of the drive motor according to the air demand.

901748 14 E ASK SFC 33
4.3 Operating panel SIGMA CONTROL 2
4.2.2 Safety devices

The following safety devices are provided and must not be modified or disabled.
■ EMERGENCY STOP control device:
Stops the machine immediately in an emergency situation. The motor is stopped. The pressure
system is vented.
■ Pressure relief valve:
The pressure relief valve protects the system against excessive pressure. It is factory set.
■ Resistance thermometer:
Monitoring the airend discharge temperature protects the compressed air system from imper‐
missible temperature rises.
■ Housing and covers for moving parts and electrical connections:
Protect against accidental contact.
4.2.3 Floating relay contacts

Floating relay contacts are provided for the transfer of signals, messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

Keys
Fig. 6 Keys – overview
Position Name Function

1 «OFF» Switches the machine off.

34 ASK SFC 901748 14 E

2 «ON» Switch on the machine.
3 «Cancel» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Accept» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.
7 «Left» Jumps to the left.
Moves the cursor position to the next left field.
8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.
13 «Time control» Switches the time control on and off.
Tab. 45 Keys
LEDs
Fig. 7 Indicators – overview

901748 14 E ASK SFC 35

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

18 Voltage applied to Continuous green light when voltage is applied to the controller.
controller
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Time control Continuous green light when the machine is in time control.
23 ON Continuous green light when the machine switched on.
Tab. 46 LEDs
RFID reader
RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided
with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 8 RFID reader

36 ASK SFC 901748 14 E
4.4 Operating modes and control modes

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

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

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

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

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

A small volume of air circulates through the bypass bore in the inlet valve, through the airend and
back to the inlet valve via the venting line.

901748 14 E ASK SFC 37
4.4.2 Control modes

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

■ DUAL
■ QUADRO
■ VARIO
Energy-efficient control modes for various applications:

Application Recommended
control mode
Compressed air station with one machine or several machines supplying VARIO
similar volumes.
Machine for peak load in a compressed air station DUAL
Machine for intermediate load in a compressed air station VARIO
Machine for basic load in a compressed air station QUADRO
Tab. 48 Energy-efficient control modes
The QUADRO control mode is preset by the factory, unless a different agreement has been made
with the manufacturer.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
QUADRO
In contrast to DUAL mode, the machine will switch in QUADRO after short periods between LOAD
to READY after being in IDLE.
Following extended times in the various operating modes, the machine switches from LOAD to
READY.
In this event, the controller considers the time in READY mode as standstill time. The time in LOAD
and IDLE operating modes are taken as minimum runtime.

38 ASK SFC 901748 14 E
4.5 Options
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
4.4.3 Variable speed drive with frequency converter (SFC)

If the machine runs in the LOAD mode, the ACTUAL value is compared with the TARGET value for
the network pressure. Depending on the pressure differential, the system controls the speed of the
drive motor and, thus, the airend.
The speed of the airend determines the delivered compressed air flow rate and the working pres‐
sure.
These changes in speed match the delivered compressed air flow rate to the air consumption and
keep the network pressure as constant and as close as possible to the system target pressure.
This functions within the control range of the machine between the minimum and maximum flow
rate (Qmin and Qmax).
If the compressed air demand falls below the minimum flow rate of the compressor (Qmin) the net‐
work pressure will continue to rise.
The machine switches to IDLE, at the latest when the pressure at the machine’s compressed air
outlet rises above the adjustable pressure rise value (pA). The pressure rise value above network
set-point pressure (pA) can be set from 0.2 to 2 bar.
Depending on the set pressure rise value, the machine will switch to IDLE or READY at
0.4 bar above maximum gauge working pressure at the latest.
This increase in pressure is to be taken into account in the design of the overall compressed
air supply system.
Further information Detailed information can be found in the SIGMA CONTROL 2 user manual.
4.5 Options
The options available for your machine are described below.
4.5.1 Option C3/C48

SIGMA CONTROL 2 controller: Connection to control technology
Connection to various control technology systems is possible with the C3 option.
Option C3 Option C48

Main Control System (MCS): Main Control System Input Output (MCSIO):
■ Slot for a communication mod‐ ■ Without slot for a communication module to connect to a
ule to connect to a control control technology system
technology system ■ Digital and analogue inputs and outputs integrated
Input-Output-Module (IOM):
■ Module with digital and ana‐
logue inputs and outputs
Tab. 49 Components

901748 14 E ASK SFC 39
4.5 Options
4.5.2 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 9 Machine mountings
4.5.3 Option W2/W3

Heat recovery
The cooling oil circuit includes 2 valves regulating the cooling oil temperature:
■ Thermostatic valve, machine
■ Thermostatic valve, heat recovery
The thermostatic valves ensure that the cooling oil is kept at the ideal temperature for machine op‐
eration.
The thermostatic valve of the heat recovery opens first so that surplus heat is released into the
heat recovery system. If the heat recovery system cannot carry away enough heat, the thermostat‐
ic valve of the machine opens to allow hot oil through the oil cooler circuit.
Condition:
Opening temperature machine thermostatic valve = Opening temperature heat recovery ther‐
mostatic valve
The heat available for recovery depends on the individual operating conditions of the machine.
A plate-type heat exchanger is installed for heat recovery.
The plate-type heat exchanger transfers heat from the cooling oil to a heat-receiving medium.
Both oil temperature regulators are equipped with working elements that ensure trouble-free func‐
tioning of the cooling and heat recovery systems.
Fig. 10 Function of the heat recovery

1 Plate-type heat exchanger

40 ASK SFC 901748 14 E
5.1 Ensuring safety

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

➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

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

5.2.1 Determining location and clearances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation of the machine room is provided below.
The clearances given are recommended and ensure unhindered access to all machine parts.
➤ Please consult KAESER if they cannot be adhered to.
Precondition The floor must be level, firm and capable of bearing the mass of the machine.

901748 14 E ASK SFC 41
Fig. 11 Recommended machine placement and dimensions [mm]

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

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

42 ASK SFC 901748 14 E
5.3 Operating the machine in a compressed air network
5.2.3 Exhaust duct design

At the cooling air inlet and exhaust, the machine can only overcome the air resistance resulting
from the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐
ing.
➤ Consult the KAESER SERVICE representative before deciding on:
■ Design of the exhaust air ducting
■ Transition between the machine and the exhaust air duct
■ Length of the ducting
■ Number of duct bends
■ Design of flaps or shutters
Further information Further information on the design of exhaust air ducts can be found in chapter 13.2.

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

901748 14 E ASK SFC 43
6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Installation work may only be carried out by authorised personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
When working on live components
Dangerous voltages persist in the frequency converter and intermediate circuit capacitors for some
time after power is switched off.
Live components are exposed when the frequency converter cabinet is opened.
➤ Work on electrical equipment may only be carried out by authorised electricians.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Before starting work on the frequency converter or intermediate circuit capacitors, wait at least
5 minutes.
➤ Check that there is no voltage on floating relay contacts.
When working on the compressed air system
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
When working on the drive system
in serious injury.

44 ASK SFC 901748 14 E
6 Installation
6.2 Reporting Transport Damage
Further information Details of authorised personnel are found in chapter 3.4.2.

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

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Connecting the machine with the compressed air network

Condensate in the compressed air network can damage the pipework:
➤ Install only corrosion-resistant pipes.
➤ Use fluoroelastomers as sealing material for seals.
➤ Note the electro-chemical voltage sequence.
➤ Consult with KAESER for suitable materials for the compressed air network.
Precondition The compressed air system is vented completely to atmospheric pressure.
Fig. 12 Compressed air pipework

1 Flexible pressure hose
2 Shut-off valve
➤ Do not induce any forces into the machine for which the compressive forces must be bal‐
anced by bracing.
1. WARNING!
Serious injury or death can result from loosening or opening components under pressure.
➤ Vent all pressurized components and chambers completely.
2. A shut-off valve must be installed by the user in the connection line.
3. Connect a flexible pressure hose.
Further information The dimensional drawing in chapter 13.2 provides the size and position of the connection ports.

901748 14 E ASK SFC 45
6 Installation
6.4 Connecting the external pressure transducer

Material Retrofit kit: "External pressure transducer SIGMA CONTROL 2"
Use suitable screened, copper-core cable (e.g.: LIYCY 2x0.75 mm2 for ambient temperatures up to
30 °C and wiring method C).
Precondition Cut-off the electrical power supply via the power supply isolating device,
ensure that the device is locked off,
verify the absence of any voltage.
Cable length between the machine and the pressure transducer: <30 m
By means of a pressure transducer, the pressure in the compressed air network can be measured
at any selected location and this signal used to regulate the compressor.
This ensures optimum compressor regulation with regard to the network pressure at the selected
location.
Safety monitoring of the machine's internal pressure is unaffected.
Your authorized KAESER SERVICE technician will be glad to provide support on planning
and executing an individual solution.
1. Install the pressure transducer at the selected location in the compressed air network.
2. Using a suitable cable, connect the pressure transducer to a spare analog input.
➤ Connect as large an area of the screening as possible to the mounting plate in the control
cabinet or use an EMC fitting to make contact.
3. When commissioning the machine with SIGMA CONTROL 2, select the <Network actual
pressure> setting in the <AII> menu.
4. Select and activate the used analog input (AII).
Further information The electrical diagram in chapter 13.3 contains further details of the pressure transducer connec‐
tion.
6.5 Connecting the machine to the power supply

Precondition The power supply is switched off,
the device is locked off,
the absence of any voltage has been verified.
The voltage in the intermediate circuit capacitors of the frequency converter is reduced.
The tolerance limits of the mains voltage (power supply) are within the permissible tolerance limits
of the rated voltage (machine).
1. The power supply must only be connected by authorised installation personnel or an author‐
ised electrician.
2. Carry out safety measures as stipulated in relevant regulations (e.g. IEC 364 or
DIN VDE 0100) and in applicable national accident prevention regulations (BGV A3 in Germa‐
ny). In addition, observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐
nect in response to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.

46 ASK SFC 901748 14 E
6 Installation
6.6 Options
5. The user is required to fit the machine with a lockable isolating device which must comply with
the requirements of EN60204-1:2006, 5.3.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the control voltage transformer is connected according to the supply voltage.
If not, change the tappings to suit the power supply voltage.
7. If provided:
Check that the tappings on the control voltage transformer in the frequency converter cabinet
are connected according to the supply voltage.
8. DANGER!
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
voltage.
9. Connect the machine to the power supply.
10. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The wiring diagram in chapter 13.3 contains further details regarding the electrical power supply
connection.
6.6 Options
6.6.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.
6.6.2 Option W2/W3

Connecting the heat recovery system
➤ Take the electrochemical series into consideration and choose suitable materials for con‐
nections.
➤ Keep the effect of pressure surges on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.
➤ Avoid very low inlet temperatures of the heat transfer medium as it can cause condensa‐
tion. If required, contactKAESER for suitable insulation measures.
WARNING
Cooling oil in the heat-receiving medium!
Oil may contaminate the medium if a leak occurs.
➤ Do not use the heat-receiving medium as drinking water.

901748 14 E ASK SFC 47
6 Installation
6.6 Options
Fig. 13 Connecting the heat recovery system

A Outlet 12 Connection port with plug
B Inlet 17 Pressure relief valve
10 Shut-off valve
1. The user is to provide the following fittings:

■ Dirt trap with max. 0.1 mm strainer mesh
■ Shut-off valves 10 and connection ports 12 for maintenance and venting.
■ Pressure relief valve 17 to prevent build-up of excessive pressure.
Actuating pressure and blow-off capacity of the safety valve are governed by the user's in‐
stallation design. The technical specification of the heat exchanger must be taken into con‐
sideration.
2. Connect the supply lines and fittings.
3. Open the shut-off valve 10 at the outlet A .
4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the
heat transfer medium.
5. Bleed the lines.
Further information The dimensional drawing in chapter 13.2 gives the flow direction, size and position of the connec‐
tion ports.

48 ASK SFC 901748 14 E
7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.

➤ Commissioning tasks may only be carried out by authorised personnel!
5 minutes.
pressure.
in serious injury.

901748 14 E ASK SFC 49
7 Initial Start-up
7.2 Instructions to be observed before commissioning


Incorrect or improper commissioning can cause injury to persons and damage to the machine.
➤ Commissioning may be carried out only by authorised installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage/standstill
Storage Measure
duration/standstill
period
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Manually fill the airend with cooling oil.
➤ Have the frequency converter intermediate circuit capacitor formed (re‐
freshed) by an authorised KAESER SERVICE technician.
36 months ➤ Have the overall technical condition checked by an authorised
KAESER SERVICE technician.
Tab. 50 Re-commissioning after storage/standstill
7.3 Checking installation and operating conditions

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

chapter
➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user-supplied lockable power supply disconnection device instal‐ 6.5
led?
➤ Are the tolerance limits of the mains voltage (power supply) within 13.3
the permissible tolerance limits of the nominal voltage (machine)?
(see nameplate in the control cabinet)
➤ Are the power supply cable conductor diameters and fuse ratings ad‐ 2.14
equate?
➤ Fan motor overload protection switch set according to the mains volt‐ 7.6
age?

50 ASK SFC 901748 14 E
7 Initial Start-up
7.4 Commissioning the Frequency Converter

chapter
➤ Have all electrical connections been checked for tightness? –
➤ Has the inspection been repeated after 50 operating hours following
the initial commissioning?
➤ Has the connection to the air system been made with a shut-off valve 6.3
and a flexible hose?
➤ Has the drive belt tension been checked? 10.9
➤ Is there sufficient cooling oil in the separator tank? 10.13
➤ Sufficient cooling oil in the airend? 7.5
➤ Machine firmly anchored to the floor? 6.6.1
(Option H1)
➤ Are all access doors closed and latched and removable panels in –
place and secured?
Tab. 51 Installation conditions checklist

The frequency converter parameters are preset. Adjustment of parameters to suit operating condi‐
tions on site is done by trained and authorised personnel.
Changes to the factory settings may influence the whole machine. The machine may break down
or be damaged.
➤ Allow only trained and authorised personnel to make parameter changes.
7.5 Pouring cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to manually add some cooling oil into the airend. In order to
avoid that the cooling oil exceeds the permissible level, drain the required quantity from the de-
pressurised oil separator tank.
Chapter 10.16 provides detailed information on how to drain cooling oil from the oil separator tank.
Material 1 l cooling oil

901748 14 E ASK SFC 51
7 Initial Start-up
7.6 Setting the motor overload protection switch
Fig. 14 Airend filling port

1 Screw plug 4 Screw plug
2 Airend 5 Belt guard
1. Remove the filler plug from the airend.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
3. Loosen the screw plugs 4 and lift the belt guard 5 .
4. Turn the rotors manually by means of the belt pulley to distribute the oil.
5. Replace the belt guard and tighten the screw plugs.
7.6 Setting the motor overload protection switch

Electrical diagram in chapter 13.3 gives the setting values for the motor overload protection switch.
In direct on-line starting, the current for the fan motor is fed via the motor overload protection
switch.
To prevent the motor overload protection switch from being triggered by voltage fluctuations,
temperature influences or component tolerances, the setting can be higher than the rated
motor current.
➤ Check the motor overload protection switch setting.
The overload protection switch shuts the machine down despite being correctly set?
➤ Contact the authorised KAESER SERVICE.
7.7 Starting the machine for the first time

Precondition No personnel are working on the machine.
All access doors are closed.
All removable panels in place and secured.
1. Open the shut-off valve to the air network.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Controller on LED is lit continuously.
3. If required:
Change the display language as described in chapter 7.10.
4. Press the «ON» key.
The compressor motor runs up and after a short time the machine switches to LOAD and deliv‐
ers compressed air.

52 ASK SFC 901748 14 E
7 Initial Start-up
7.8 Checking the direction of rotation
➤ Watch for any faults occurring in the first hour of operation.

➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
7.8 Checking the direction of rotation

The machine is designed for a clockwise phase sequence.
In frequency-controlled compressors, the direction of rotation of the fan motor may be incorrect
even if the compressor motor is correct.
Ideally, the direction of phase rotation should be measured with a phase sequence meter.
Alternatively, start the machine very briefly and observe the direction of rotation of the motor cool‐
ing fan.
1. Check the direction of phase rotation with a phase sequence meter at the inlet lines of the fan
motor.
2. If the fan motor is incorrect, change the machine supply phases L1 and L2.
You do not have a phase sequence meter?
➤ Switch the machine on and off again the moment the drive motor begins to turn.
➤ Compare the direction of rotation of the fan with the arrow on the motor casing.
7.9 Setting the set point pressure

The system pressure pA is factory set to the highest possible value.
Adjustment is necessary for individual operating conditions.
Do not set the set point pressure of the machine higher than the maximum working pressure
of the compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To reduce the cycling (toggling) frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.
➤ Set the set point pressure as described in the SIGMA CONTROL 2 operating manual.
7.10 Setting the display language

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.

901748 14 E ASK SFC 53
7 Initial Start-up
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
6.1 bar 80.0 ° C
–––––––– de_DE Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.
Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.

54 ASK SFC 901748 14 E
8 Operation
8.1 Switching on and off
8 Operation
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.
Fig. 15 Switching on and off

1 ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Voltage applied to controller LED
8.1.1 Switching on
All access doors and panels are closed and secure.
1. Switch on the power supply isolating device.

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

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

901748 14 E ASK SFC 55
8 Operation
8.2 Switching off in an emergency and switching on again
Result The Voltage applied to controller LED extinguishes. The machine is switched off and disconnected
from the mains supply.
In rare cases, you may want to shut down the machine immediately and cannot wait until the
automatic shut-down process is finished.
➤ Press «OFF» once again.

The EMERGENCY STOP control device is located below the control panel.
Fig. 16 Switching off in an emergency

9 EMERGENCY STOP control device
Switching off
➤ Press the EMERGENCY STOP control device.
Result The EMERGENCY STOP control device remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
Precondition The fault has been rectified
1. Turn the EMERGENCY STOP control device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Using the remote control for switching on and off

Precondition A link to the remote control centre exists.

56 ASK SFC 901748 14 E
8 Operation
8.4 Using the timer for switching on and off
Fig. 17 Using the remote control for switching on and off

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

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 52 Machine identification
2. Label the starting device in the remote control centre as follows:

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 53 Remote control identification
3. Press the «remote control» key.

The remote control LED lights. The machine can be remotely controlled.

Precondition The timer is programmed.

901748 14 E ASK SFC 57
8 Operation
8.5 Interpreting operation messages
Fig. 18 Using the timer for switching on and off

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

2. Press «Timer».
The time control LED lights. The timer switches the machine on and off.

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O.
8.6 Acknowledging alarm and warning messages

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

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

58 ASK SFC 901748 14 E
8 Operation
Fig. 19 Acknowledging messages

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

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

maintenance has been carried out.

The Warning LED extinguishes.
Further information Please refer to the SIGMA CONTROL 2 operating manual for a list of possible warning messages
during operation.

901748 14 E ASK SFC 59

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

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

60 ASK SFC 901748 14 E
9.2 Other faults

Cooling oil leaking into the ma‐ Hose coupling or maintenance Remove coupling or mainte‐
chine interior. hose still plugged into the nance hose.
oil separator tank.
Oil cooler leaking. Call KAESER SERVICE.
Leaking pipe joints. Tighten pipe joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐
high. ing oil.
Oil separator cartridge split. Changing the oil separator car‐
tridge
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line clogged. Check the dirt trap strainer in
the oil return line.
Tab. 55 Other faults and remedies

901748 14 E ASK SFC 61
10 Maintenance
10.1 Ensuring safety
10 Maintenance
Follow the instructions below to ensure safe machine maintenance.

➤ Allow maintenance work to be performed by authorised personnel only.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 56 Advise others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed.
voltage is present.
5 minutes.
pressure.

62 ASK SFC 901748 14 E
10 Maintenance
10.2 Following the maintenance plan
➤ Vent all pressurized components and enclosures.
in serious injury.
voltage is present.


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

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.19.
10.2.2 Resetting maintenance interval counters

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

901748 14 E ASK SFC 63
10 Maintenance
Precondition Maintenance performed and

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

The table below lists the required maintenance tasks.
➤ Take note of the controller's warning messages and carry out tasks punctually, taking ambient
and operating conditions into account:
Interval Maintenance task See chapter

Weekly Check the cooling oil level. 10.13
Cooler: 10.3
Check the filter mat
Control cabinet: 10.4
up to 1000 h Clean the cooler. 10.5
Check the air filter. 10.7
Cooler: 10.3
Clean the filter mat.
up to 3000 h Control cabinet: 10.4
Change the filter mat.
Cooler: 10.3
Display: Maintain the drive belt. 10.9
SIGMA CONTROL 2 Change the air filter. 10.7
Display: Change the oil filter. 10.17
SIGMA CONTROL 2
Every 1 years at the lat‐
est
Display: Change the oil separator cartridge. 10.18
SIGMA CONTROL 2
est
Variable, see table 58 Change the cooling oil. 10.16
up to 12000 h Replace the drive belt. 10.9
h = operating hours

64 ASK SFC 901748 14 E
10 Maintenance
Interval Maintenance task See chapter

Every 1 years at the lat‐ Check the safety valve. 10.10
est Check the function: 10.11
Safety shut-down due to excessive airend discharge tem‐
perature
Check the EMERGENCY STOP device. 10.12
Check the cooler for leaks. 10.5
Maintain the heat recovery system. 10.6
Check that all electrical connections are tight. –
h = operating hours
Tab. 57 Regular maintenance tasks
10.2.4 Cooling oil Change interval

Duty cycles and ambient conditions are important factors influencing the number and length of the
oil change intervals.
KAESER SERVICE will support you in determining appropriate intervals and provide informa‐
tion on the possibilities of oil analysis.
➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary; log the results in table 58 for fu‐
ture reference.
Maximum permissible oil change interval

[operating hours/years]
SIGMA FLUID Favourable operating Unfavourable operat‐ My operating condi‐
conditions* ing conditions tions
S-460 6000**/2 4000/1
S-570 6000**/2 4000/1
MOL 3000/1 2000/1
FG-460 3000/1 2000/1
FG-680 3000/1 2000/1
PANO‐ 3000/1 2000/1
LIN HLP SYNTH 46
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Change intervals of >6000 perating hours are not permissible without an oil analysis.
Tab. 58 Cooling oil Change intervals
10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Have an authorised KAESER SERVICE technician carry out service tasks.

901748 14 E ASK SFC 65
10 Maintenance
10.3 Cooler: Cleaning or Renewing the Filter Mats
➤ Have service tasks carried out in a timely manner, taking the ambient and operating conditions
into account:
Interval Service task

Display: Service valves.
SIGMA CONTROL 2 Compressor drive motor:
Replace the motor bearings.
Fan motor:
up to 36000 h Have the plastic pipes and hose lines replaced.
est.
up to 36000 h Replace the control cabinet fan.
After 20 years at the lat‐ Replace safety-relevant components of the safety functions.
est
h = operating hours
Tab. 59 Regular service tasks

The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the
components is no longer ensured.
Material Filter mats:

Warm water and household detergent
Spare parts (as required)
Precondition The machine is switched off.
Fig. 20 Filter mat for the air and oil cooler

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

1. Carefully remove the filter mat from the retaining frame.

66 ASK SFC 901748 14 E
10 Maintenance
10.4 Control cabinet: Clean or renew the filter mat
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Change the filter mat if cleaning is not possible or if the change interval has expired.
4. Carefully insert the filter mat in the retaining frame.

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

Precondition The power supply isolator is switched off (all poles),

the device is secured to prevent switching back on,
the absence of voltage has been verified.
The machine has cooled down.
Fig. 21 Switching cabinet ventilation

1 Ventilation grille
2 Filter mat
1. Carefully remove the ventilation grille and take out the filter mat.
3. Replace the filter mat if cleaning is not possible or if the change interval has expired.
4. Insert the filter mat in the frame and latch in the ventilation grille.
10.5 Cooler maintenance

Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.

901748 14 E ASK SFC 67
10 Maintenance
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the motors resulting in increased wear
and tear.
➤ Have the authorised KAESER SERVICE technician clean the cooling air ducts.
Material Brush and vacuum cleaner

Face mask (as required)
Precondition The power supply isolating device is switched off,


1 Filter mat
Cleaning the cooler and radiator
A filter mat helps to keep the cooler clean. Despite this fact, the cooler will clog over a period of
time.
Do not use sharp objects to clean the cooler. It could be damaged.
Avoid creating clouds of dust.
2. Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
➤ Have stubborn clogging removed by an authorized KAESER SERVICE technician.
Checking the cooler for leaks
➤ Carry out visual inspection: Did cooling oil escape?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by a KAESER SERVICE technician.

68 ASK SFC 901748 14 E
10 Maintenance
10.6 Maintain the heat recovery system
10.6 Option W2/W3

Maintain the heat recovery system
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is depend‐
ant on the characteristics of the heat transfer medium.
Pressure in the cooling oil circuit is generally higher than that in the heat recovery system. If a leak
occurs, oil will run into the heat-receiving medium. Increased cooling oil loss can indicate a leaking
heat exchanger.
1. Check the heat exchanger visually for leaks.

2. Have KAESER SERVICE check the heat exchanger for internal leaks and clean if contamina‐
ted.
10.7 Air Filter Maintenance

Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress the pressure system and cause damage to the machine.
The air filter element cannot be cleaned.
Material Replacement part
Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.
Fig. 23 Air filter maintenance

1 Snap fastener
2 Air filter element
3 Air filter housing
1. Release the spring clips and remove the element.

2. Clean all parts and sealing surfaces.

901748 14 E ASK SFC 69
10 Maintenance
10.8 Motor maintenance
3. Insert the new element in the housing.

4. Clip the air filter housing onto the inlet valve.
10.8 Motor maintenance

The drive motor and fan motor anti-friction bearings are permanently greased. Re-greasing is not
necessary.
➤ Have the anti-friction bearings checked by an authorised KAESER SERVICE technician in the
course of a maintenance visit.
10.9 Drive belt maintenance

Material Spare parts (if required)
WARNING
Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐
ties.
➤ Switch off and lock out the power supply isolating device and verify the absence of volt‐
age.
Fig. 24 Drive belt maintenance

1 Nut 4 Screw plug
2 Nut 5 Belt guard
3 Marker pin (shown as: belt tensioning re‐
quired)
Checking belt tension and adjustment
The tensioning device uses spring force to apply correct tension to the belt.

70 ASK SFC 901748 14 E
10 Maintenance
10.10 Testing the pressure relief valve
Adjust the tension when the marker pin reaches the top end of the elongated hole.
The marker pin can be seen through a viewing window from outside. This means that belt tension
can be checked without opening the machine.
1. Loosen the nut 2 .
2. Use the adjusting nut 1 to adjust spring tension until the marker pin reaches the lower end of
the elongated hole.
3. Retighten the locking nut 2 .
Visually check for damages.

2. Manually turn the pulley so that all of the belt can be inspected for damage.
3. In case of damage: Replace the drive belt immediately.
Replace the drive belt.

2. Loosen the nut 2 .
3. Turn adjusting nut 1 to loosen the tension on the belts until they can be removed from the pul‐
ley.
4. Install the new set of belts and use the adjusting nut 1 to adjust tension until the marker pin
reaches the lower end of the elongated hole.
5. Retighten the locking nut 2 .

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blow off protection and air system pressure monitoring are switched off during the test. In normal
operation, the blow-off protection will switch off the machine before the pressure relief valve re‐
sponds. During the inspection, the blow-off protection will switch off the machine only when the ac‐
tivating pressure of the pressure relief valve has been exceeded by 1 bar.
➤ Follow the detailed description of this procedure in theSIGMA CONTROL 2 operating
manual
➤ Never operate the machine without a correctly functioning pressure relief valve.
➤ Have a defect pressure relief valve replaced immediately.
WARNING
Excessive noise is caused when the pressure relief valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear hearing protection.
1. Close the user's shut-off valve between the machine and the air distribution network.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)

901748 14 E ASK SFC 71
10 Maintenance
10.11 Check the safety shut-down due to excessive airend discharge temperature.
3. Log on to SIGMA CONTROL 2 with access level 2.

4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. WARNING!
Risk of burns due to released cooling oil and compressed air when blowing off the pressure
relief valve!
➤ Wear eye protection.
6. End the test as soon as the pressure relief valve blows off or working pressure exceeds the
activating pressure of the pressure relief valve by nearly 1 bar.
7. If necessary, vent the machine and replace the defective pressure relief valve.
8. Deactivate the test function
9. Open the user's shut-off valve between the machine and the air distribution network.
10.11 Check the safety shut-down due to excessive airend discharge

temperature.
The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
The machine does not shut down?
➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐
nician.
10.12 Check the EMERGENCY STOP control device
Fig. 25 Check the EMERGENCY STOP control device

Precondition Compressor motor running
1. Press the EMERGENCY STOP control device.

The compressor motor stops, the pressure system is vented, and the machine is prevented
from automatically re-starting.
The compressor motor does not stop?
The safety function of the EMERGENCY STOP device is no longer ensured.
➤ Shut down the machine immediately and call KAESER SERVICE.

72 ASK SFC 901748 14 E
10 Maintenance
10.13 Checking the cooling oil level
2. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
3. Acknowledge the alarm message.

In frequency-controlled compressors (SFC) the cooling oil level indicator is only accurate
when the machine is running at or near maximum speed.
The lower the pressure at the compressed air outlet, the higher the speed.
The SIGMA CONTROL 2 displays this value.
Precondition The machine has been running at least 5 minutes in LOAD mode.
Fig. 26 Checking the cooling oil level

1 Oil level minimum
2 Oil level maximum
3 Oil level optimum
1. CAUTION!
Danger of burning - hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.
2. Check the cooling oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Top up the cooling oil.
10.14 Venting the machine (de-pressurising)

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.

901748 14 E ASK SFC 73
10 Maintenance
Material The hose coupling, shut-off valve and maintenance hose required for venting lie beneath the oil
separator tank.
CAUTION
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.
Fig. 27 Venting the machine

1 Hose coupling (air cooler venting) 7 Shut-off valve
2 Pressure gauge A Shut-off valve open
3 Hose coupling (oil separator tank venting) B Shut-off valve closed
6 Plug-in nozzle 8 Maintenance hose
Isolating the machine from the air system
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
Venting the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 bar.

74 ASK SFC 901748 14 E
10 Maintenance
10.15 Replenish cooling oil
The pressure gauge does not read 0 bar after automatic venting?
➤ Make sure that the user's shut-off valve is closed or that the complete air system is ven‐
ted.
➤ With the shut-off valve closed, insert the plug-in nozzle 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
the authorised KAESER SERVICE.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/check valve.
1. With the shut-off valve closed, insert the plug-in nozzle 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

separator tank.

901748 14 E ASK SFC 75
10 Maintenance
Fig. 28 Replenish cooling oil

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

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

CAUTION


76 ASK SFC 901748 14 E
10 Maintenance
ted.
sure/check valve.
10.15.2 Topping up with cooling oil and trial run

Replenish cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. WARNING!
Compressed air!
Compressed air and components under pressure can injure or cause death if the contained
energy is suddenly released.
➤ Fully vent all pressurised components and enclosures.
2. NOTICE!
The machine could be damaged by unsuitable oil!
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
3. Open the filler plug 4 slowly.
4. Top up to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.
Starting the machine and performing a trial run
1. Close all access doors, replace and secure all removable panels.
3. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.
4. Switch off the machine and check for leaks.

901748 14 E ASK SFC 77
10 Maintenance
10.16 Changing the cooling oil

Drain the oil completely from the following components in the sequence shown:
■ Oil separator tank
■ Oil cooler
■ Airend
■ Heat exchanger (Option W2/W3)
Always change the oil filter and oil separator cartridge when changing the oil.
Compressed air helps to expel the oil. This compressed air can be taken either from the compres‐
sor itself or from an external source.
An external source of compressed air is necessary in the following cases (examples):

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.
Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve is stowed beneath the oil separator
tank.
CAUTION
There is risk of burns from hot components and oil!
➤ Wear long-sleeved clothing and gloves.
Fig. 29 Changing the cooling oil, pressuring the oil separator tank
7 Shut-off valve 10 Shut-off valve (venting line)

78 ASK SFC 901748 14 E
10 Maintenance
Changing the cooling oil with internal pressure Oil change with an external compressed air
source
The machine has been running for, at least, The power supply isolating device is switched
5 minutes in LOAD mode. off,
The machine is fully vented, the device is locked off,
the pressure gauge on the oil separator tank the absence of any voltage has been verified.
reads 0 bar. The machine is fully vented,
1. Close the shut-off valve 10 in the venting the pressure gauge on the oil separator tank
line. reads 0 bar.
2. Start the machine and watch the oil separa‐ An external source of compressed air is availa‐
tor tank pressure gauge 2 until it reads 3– ble.
5 bar. 1. Close the shut-off valve 10 in the venting
3. Switch off the machine. line.
4. Wait at least 2 minutes to allow the oil to 2. With the shut-off valve closed, insert the
flow back to the separator tank. plug-in nozzle 6 into the hose coupling 3 .
5. Switch off and lock out the power supply 3. Connect the maintenance hose to the exter‐
isolating device and verify that no voltage is nal air supply.
present. 4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3 –
5 bar.
5. Close the shut-off valve 7 and remove the
plug-in nozzle from the coupling.
Draining the cooling oil from the separator tank
Contact KAESER SERVICE if condensate is detected in the cooling oil.

It is necessary to adapt the airend discharge temperature to individual ambient conditions.
Fig. 30 Changing the cooling oil Oil separator tank

6 Plug-in nozzle 9 Hose coupling (oil drainage)
7 Shut-off valve 11 Shut-off valve (oil drainage)
8 Maintenance hose
1. Prepare a cooling oil receptacle.

3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut-off valve 7 in the maintenance hose and allow the cooling oil to drain
completely.
6. Close the shut-off valve 11 and unplug the male hose fitting.

901748 14 E ASK SFC 79
10 Maintenance
➤ Dispose of used oil in accordance with environment protection regulations.
Draining the oil from the cooler
Fig. 31 Changing the cooling oil Oil cooler

1 Oil cooler 6 Plug-in nozzle
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve 8 Maintenance hose

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

80 ASK SFC 901748 14 E
10 Maintenance
Draining the oil from the airend
Fig. 32 Changing the cooling oil Airend

2 Hose coupling (oil drainage) 6 Plug-in nozzle
3 Shut-off valve 7 Shut-off valve
4 Screw plug 8 Maintenance hose
5 Belt guard 9 Belt pulley

4. Open the shut-off valves 3 and 7 .
6. Rotate the pulley 9 for at least five times to ensure that the entire cooling oil has drained off.
8. Close the shut-off valve 3 and remove the plug-in nozzle.
Result The cooling oil is drained from the airend.

A small amount of cooling oil may flow back into the oil separator tank as a result of turning the
pulley.
Repeat the procedure for draining oil from the separator tank to remove this oil.

901748 14 E ASK SFC 81
10 Maintenance
Option W2/W3 Draining the oil from the heat exchanger
Fig. 33 Changing the cooling oil Heat recovery

1 Hose coupling 7 Shut-off valve
6 Plug-in nozzle

2. Insert the male hose fitting 6 in the hose coupling 1 .
4. Open the shut-off valves 3 and 7 and allow the oil to drain completely.
Filling with cooling oil
Fig. 34 Changing the cooling oil Filling with cooling oil

2 Pressure gauge 5 Cooling oil level indicator
4 Cooling oil inlet port with screw plug 10 Shut-off valve (venting line)
1. Open the shut-off valve 10 in the venting line.

2. WARNING!
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.

82 ASK SFC 901748 14 E
10 Maintenance
10.17 Changing the oil filter
4. Fill in cooling oil.

5. Check the screw plug ring seal for damage and screw the plug back in again.
3. Switch on the electrical power supply via the power supply isolating device and reset the main‐
tenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, top up if necessary.
5. Switch off the machine and visually check for leaks.

Material Spares

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

1 Oil filter
2 Direction to unscrew

901748 14 E ASK SFC 83
10 Maintenance
10.18 Changing the oil separator cartridge
Changing the oil filter
1. WARNING!
Compressed air!
2. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐
ronmental protection regulations.
3. Lightly oil the new filter's gasket.
4. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a trial run
3. Switch on the power supply and reset the maintenance interval counter.
5. Switch off the machine and check visually for leaks.

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

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

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.

84 ASK SFC 901748 14 E
10 Maintenance
Fig. 36 Changing the oil separator cartridge

14 Cover 20 Screw connection
15 Dirt trap 21 seal
16 Air pipe 23 Oil separator cartridge
17 Retaining screw 30 Ball (functioning as a check valve)
19 Self-locking nut 31 Strainer
Changing the oil separator cartridge
1. WARNING!
Compressed air!
Compressed air and pressurised devices can cause serious injury or death if the contained
2. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
3. Unscrew the nut 19 and turn the air pipe 16 to one side.
4. Remove the cover fixing screws 17 and carefully remove the cover 14 .
5. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac‐
cording to environmental protection regulations.
6. Clean all sealing faces.
7. Insert the new oil separator cartridge with gaskets and re-fix the cover.
8. Renew the O-ring and strainer in the dirt trap 15 .
➤ Make sure the ball 30 is properly seated.
The ball prevents cooling oil being pressed into the separator cartridge.
9. Attach the air pipe to the cover 14 with a new, self-locking nut.
10. Replace and tighten all fittings.

901748 14 E ASK SFC 85
10 Maintenance
Start the machine and carry out a trial run
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.

86 ASK SFC 901748 14 E
10 Maintenance
10.19 Documenting maintenance and service work

Machine number:
➤ Enter maintenance and service work carried out in the list.
Date Maintenance task carried out Operating hours Signature
Tab. 60 Logged maintenance tasks

901748 14 E ASK SFC 87
11.1 Note the nameplate

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

KAESER consumable parts and operating materials are original KAESER products. They are spe‐
cifically selected for use in KAESER machines.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from damage.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spares or operating fluids/materials.
➤ Use only original parts and operating fluids/materials.
➤ Have an authorized KAESER SERVICE technician carry out regular maintenance.
Machine
Name Number
Air filter element 1250
Filter mat (cooler) 1050
Filter mat (control cabinet) 1100
Oil filter 1200
Oil separator cartridge 1450
Cooling oil 1600
Drive belt 1801
Condensate drain: —
Service-Unit
Tab. 61 Consumable parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,
■ The security of genuine KAESER spares.
■ Increased legal certainty as all regulations are kept to.

88 ASK SFC 901748 14 E
11.4 Replacement parts for service and repair
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.

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

901748 14 E ASK SFC 89

90 ASK SFC 901748 14 E

901748 14 E ASK SFC 91
12.1 De-commissioning

De-commissioning is necessary, for example, under the following circumstances:
■ The machine is (temporarily) not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.
➤ The following tasks must be carried out only by authorised personnel.
12.1.1 Temporary de-commissioning

Precondition The machine can be started at regular intervals.
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.
12.1.2 Long-term de-commissioning

Precondition Immediately prior to de-commissioning, run the machine in LOAD operation for at least 30 minutes.
12.1.2.1 Draining condensate
If the machine is equipped with a condensate drain, then drain the condensate from the conden‐
sate drain.
1. Drain condensate from the condensate drain and dispose of according to applicable environ‐
mental protection regulations.
2. Remove the user-supplied condensate lines.
12.1.2.2 Isolating the machine from supply lines

it has been locked off against unintentional reactivation and
The machine is fully vented (depressurised).
The user's shut-off valve to the compressed air network is closed or the compressed air network
has been fully vented.
1. Allow the machine to completely cool down.

2. Detach the power supply and connecting line to the compressed air network at the user side.
3. Option W2/W3:
Detach the user connecting lines and use compressed air (<2 bar) to blow out the heat recov‐
ery system until liquid no longer escapes.
4. Properly close all open connecting ports.

92 ASK SFC 901748 14 E
12.2 Packing
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact
KAESER SERVICE for more information.
Material Desiccant
Plastic sheeting
Wooden crate
Precondition The machine is decommissioned.

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

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
The following measures also apply to machines not yet commissioned.
Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. NOTICE!
Moisture and frost can damage the machine!
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Mass and centre of gravity determine the most suitable method of transportation. The centre of
gravity is shown in the drawing in chapter 13.2.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only by forklift truck or lifting gear and only by personnel trained in the safe transportation
of loads.
➤ Ensure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The whole machine is over the forks.

901748 14 E ASK SFC 93
12.4 Transport
Fig. 37 Transporting with a forklift truck
1. Take note of the centre of gravity.

2. Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transport with a hoist

Only suitable and approved load-carrying and attachment devices ensure proper transport of the
machine with a hoist (e.g., crane). Suitable crossbeams ensure sufficient distance of the attach‐
ment resources from the machine housing to prevent damage.
The machine is not equipped with fastening points.
Examples of unsuitable fastening points:

■ Pipe sockets
■ Flanges
■ Attached components such as centrifugal separators, condensate drains or filters
■ Rain protection covers
➤ Consult KAESER if you require suitable load-carrying and attachment devices or have
questions regarding the correct use.
Precondition Load-carrying and attachment devices meet the local safety regulations.
The hoist, load-carrying and attachment devices or the lifted machine do not endanger personnel.

94 ASK SFC 901748 14 E
12.4 Transport
Fig. 38 Transporting with a crane

1 Load carrying devices
2 Attachment resources
3 Crossbeam
1. WARNING!
Risk of accident caused by incorrect use of load-carrying and attachment devices!
➤ Comply with permissible load limits.
➤ Comply with specific safety information of used load-carrying and attachment devices.
2. Properly use load-carrying and attachment devices:
■ Ensure proper distribution of the fastening points relative to the centre of gravity position
(symmetrical load distribution).
■ Ensure equal slope angles of 15° to 45° for attachment devices with multiple strands.
─ Slope angles between 45° and 60° may be unsuitable.
─ Slope angles larger than 60° are prohibited.
■ Ensure the maximum incline of 6° of the machine to the horizontal.
■ Ensure sufficient distance of the attachment devices to the machine.
■ Ensure a positive stability height: Dimension B > Dimension A
■ Do not attach the attachment devices to any machine component.
3. Carry out a lifting test:
Slightly lift the machine to check whether machine remains in horizontal position and does not
teeter.
4. Transport the machine only after a successful lifting test.

901748 14 E ASK SFC 95
12.5 Disposal
12.5 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
1. Completely drain the cooling oil from the machine.

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

➤ Refrigerant and oil must be drained and disposed of by an authorized specialist workshop.
12.5.1 Battery disposal in accordance with local environmental regulations.

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be delivered to the
national battery collection system. This procedure facilitates the handling and recycling of batteries.
In EU Member States, as per Directive 2006/66 / EC, used batteries must be returned to the point
of sale or to a disposal system (free of charge). These disposal facilities may be local recycling
yards for used electric and electronic devices and their points of sale.
The SIGMA CONTROL 2controller’s enclosure houses a battery.
Fig. 39 Battery labelling

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

friendly manner.
You actively contribute to the protection of our environment when you bring used batteries to
the appropriate recycling system.
Further information Refer to the SIGMA CONTROL 2user manual for details regarding battery removal and replace‐
ment.

96 ASK SFC 901748 14 E
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram)
13 Annex

901748 14 E ASK SFC 97
13 Annex

98 ASK SFC 901748 14 E
13 Annex

901748 14 E ASK SFC 99
13 Annex

100 ASK SFC 901748 14 E
13 Annex

901748 14 E ASK SFC 101
13 Annex

102 ASK SFC 901748 14 E
13 Annex
13.2 Dimensional drawing

901748 14 E ASK SFC 103
104
1110
Outlet: compressed air
514 56 340 Outlet: cooling air
Inlet:
cooling air
Inlet:
cooling air
514
ID G 1 1/4
620
13
Inlet:
13.2
Inlet: intake air

intake air
1530
W2 W3
ASK SFC
ID G 3/4
Subject to development-related changes.

Drawing may be altered only via CAD.
Inlet:
cooling air
890
850
48
735
Operating Manual
140
Annex
193
56 45
Z 60 680 O 100
192
100
124 800 70 870
Electrical connection
1010
Dimensional drawing
3
58 H1
x
O H1
60
O
140
26

40
40
60 680 O 13
100
590
180° O 140
280
70 870
90°
326
90°
570
262
646 32
ID : Internal thread
Change number Projection Scale Date Name
34298 1:15 Drawn 11.02.2014 WACHSMANN1
Document TZM Original Edited 14.02.2014 WACHSMANN1 Language Sheet
10260304 E 01 A2 Released 14.02.2014 SCHUBT4 E 1/1
: Center of gravity
Position marginally dependent on design W3 int. heat recovery ΔT=55K Document TZD Designation
W2 int. heat recovery ΔT=25K 10260304 D 01
ASK.3 SFC K1
H1 Machine mountings Status Dimension and connection dim.
Transport opening ≥ machine width + 100mm Released
Drawings remain our exclusive property.

They are entrusted only for the agreed upon purpose.
Copies or any other reproduction, including storage, treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose.
Neither originals nor reproductions may be given to or made available to third parties.
Stand 17.10.2013
K1 Air cooling
901748 14 E
901748 14 E
.
ASK 28/34 : V = 4.000m³/h
. Outlet: cooling air
ASK 40 : V = 5.000m³/h
405
514 56
13
13.2
Inlet:
cooling air
ASK SFC
514
565

.
ASK 28/34 : V = 3.300m³/h
.
Operating Manual
ASK 40 : V = 4.300m³/h
Annex
25
540 25
890
Dimensional drawing
max. drilling depth 15mm

696
25
326
25
262
312
646 32
max. drilling depth 15mm
382 Change number Projection Scale Date Name
1:15 Drawn 14.11.2013 ROEBLITZ1
Document TZM Original Edited 02.01.2014 ROEBLITZ1 Language Sheet
Total permissible pressure loss for installed ducting
Document TZD Designation
with filtermats 10260361 D 00
ASK.3 K1
ASK 28/34 ∆ p max . 60 Pa (6 mm water column)
Status Connection, dp cool. air duct
ASK 40 ∆ p max . 40 Pa (4 mm water column) Released

Stand 17.10.2013
K1 Air cooling
105
13 Annex
13.3 Electrical Diagram

106 ASK SFC 901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
Electrical diagrams
Compressor series ASK SFC
13
Air cooled
13.3
ASK SFC
380V±10% 60Hz 440V±10% 60Hz
Operating Manual
400V±10% 50Hz 460V±10% 60Hz
Annex
TT/TN three-phase power supply with neutral point grounding

Electrical Diagram
ATTENTION !!!
The document gives collective information on Manufacturer: KAESER KOMPRESSOREN SE
power supply voltages and frequencies for all machines.

The voltage and frequency and local conditions under 96450 Coburg
which any particular machine may be used
are given on the nameplate of the machine GERMANY
and in the accompanying service manual.
The drawings remain our exclusive property. They are entrusted

only for the agreed purpose. Copies or any other reproductions,
including storage, treatment and dissemination by use of
electronic systems must not be made for any other than the
agreed purpose. Neither originals nor reproductions must be
forwarded or otherwise made accessible to third parties.
c Datum 26.07.2018 E Cover page =

b Bearbeiter Sitter +
a Geprüft Geiger
Compressor ASK SFC page 1
A Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS DASK.F-03067.02 1 Bl.
107
108
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
1 Cover page DASK.F-03067.02 1
2 List of contents ZASK.F-03067.02 1
3 general instructions UASK.F-03067.02 1
4 electrical equipment identification UASK.F-03067.02 2
5 Equipment parts list UASK.F-03067.02 3
8 Circuit diagram Power switching SASK.F-03067.02 1
13
13.3
9 Circuit diagram Fan motor / Control cabinet ventilator SASK.F-03067.02 2

10 Circuit diagram Control voltage tapping / Safety chain SASK.F-03067.02 3
ASK SFC
11 Circuit diagram Power supply unit SASK.F-03067.02 4
12 Circuit diagram IO-module / Configuration SASK.F-03067.02 5
13 Circuit diagram sensors / actuators SASK.F-03067.02 6
Operating Manual
14 Circuit diagram Binary inputs / outputs FC SASK.F-03067.02 7
Annex
15 Circuit diagram Volt-free contacts SASK.F-03067.02 8

16 Circuit diagram inputs SASK.F-03067.02 9
17 Circuit diagram digital outputs SASK.F-03067.02 10
18 Circuit diagram transformer diagrams SASK.F-03067.02 11
19 Circuit diagram Handling: Terminals / Feed line connection SASK.F-03067.02 12
Electrical Diagram
20 Terminal schedule screen rail/- FC, Terminal strip -X0,-X2 KASK.F-03067.02 1

21 Terminal schedule Terminal strip -X11 KASK.F-03067.02 2
22 Component layout Switchboard AASK.F-03067.02 1

c Datum 26.07.2018 List of contents =
a Geprüft Geiger
B Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS ZASK.F-03067.02 1 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
general instructions control cabinet wiring for non-designated conductors
with multi-standard stranded conductors
ATTENTION !!!
primary circuits: black
Install supplies, grounding and shock protection
to local safety regulations. Control voltage AC ungrounded: red 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Control voltage AC grounded: white 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Do not make or break
13
13.3
live plug-in connectors. Control voltage DC ungrounded: blue 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
ASK SFC
Control voltage DC grounded: white/blue 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
external voltage: orange 1,5mm² H07V-K, 16AWG UL-Style 1015, CSA-TEW
measuring circuits: violet 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Operating Manual
Annex
earth conductor: green/yellow H07V-K, UL-Style 1015, CSA-TEW

Electrical Diagram

c Datum 26.07.2018 general instructions =
a Geprüft Geiger
C Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS UASK.F-03067.02 5 Bl.
109
110
1 2 3 4 5 6 7 8
electrical equipment identification

general components Control sensors/actuators
-F4 Overload protection switch, Fan motor -K20 Main Control System SC2 MCS -B1 Pressure transducer, Air main pressure
-F11 Overload protection switch, Control transformer -X1 Ethernet -B2 Direction of rotation pressure switch
-X2 IO-Bus -B40 Temperature probe,
-K53,-K54,-K55 Coupling relay -X3 RS485-FC (USS) Airend discharge temperature
-X4 Communication module (Bus)
13
13.3
-M1 Compressor motor -X5 SD card slot -K1 Control valve

-M4 Fan motor -X6 Earth connection
ASK SFC
-M7.1,-M7.2 Control cabinet ventilator
-K21 IO-module SC2 IOM-1
internal
Operating Manual
-Q4 Contactor, Fan motor
Annex
-X1 IO-Bus, Input

-X2 IO-Bus, Output
-R2 Ferrit bead -X3,-X8 digital inputs
-R3 Tape-wound core
-X4 Power supply unit,
digital outputs
-S1 EMERGENCY STOP pushbutton
Electrical Diagram
-X5,-X9 Relay outputs

-X6 Analog input, 4-20mA
-T1 Frequency converter -X7 Analog input, Pt100
-T11 Control transformer
-T21 Power unit external
-X11...-X13 analog inputs, 4-20mA

-X14...-X17 analog inputs, Pt100
-X18...-X29 digital inputs
-X30...-X32 digital outputs
terminal strips
-X0 Terminal strip, Power supply
-X2 Terminal strip, Control FC
-X11 Terminal strip, Control
c Datum 26.07.2018 electrical equipment identification =

a Geprüft Geiger
SC2 MCS UASK.F-03067.02 5 Bl.
901748 14 E
13 Annex
3
performance-related components
Bl.
5
page
model ASK 34 SFC
machine power supply 380 V ±10 %, 60 Hz 400 V ±10 %, 50 Hz 440 V ±10 %, 60 Hz
460 V ±10 %, 60 Hz
UASK.F-03067.02
=
+
Control voltage 230 V 230 V 230 V
Motor -M1 18,5 kW 18,5 kW 18,5 kW
Motor -M4 0,55 kW 0,55 kW 0,55 kW
supply connection fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12
PE rail Torque 10 Nm 10 Nm 10 Nm
Terminal strip -X0 3x 895314.0 3x 895314.0 3x 895314.0
Wago 285-150 285-150 285-150
Stripped length X 30 mm 30 mm 30 mm
Handling fig. 2, Sht. 12 fig. 2, Sht. 12 fig. 2, Sht. 12
Frequency converter -T1 7.8833.01130 7.8833.01130 7.8833.01130
SC2 MCS
6SL3210-1PE24-5AL0 6SL3210-1PE24-5AL0 6SL3210-1PE24-5AL0
22 kW, 380 V-480 V 22 kW, 380 V-480 V 22 kW, 380 V-480 V
Control Unit 7.7830.00710 7.7830.00710 7.7830.00710
Siemens 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1
Circuit breaker -F4 7.8742.01120 7.8742.01120 7.8742.01120
3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10
1,4-2 A 1,4-2 A 1,4-2 A
setting: 1,9 A setting: 1,8 A setting: 1,6 A (460 V)
setting: 1,7 A (440 V)
Auxiliary switch 7.8742.05000 7.8742.05000 7.8742.05000
Compressor ASK SFC

Siemens 3RV2901-1E 3RV2901-1E 3RV2901-1E
Contactor -Q4 7.8740.00040 7.8740.00040 7.8740.00040
3RT2023-1AL20 3RT2023-1AL20 3RT2023-1AL20
Equipment parts list

Interference suppressor 7.8740.05110 7.8740.05110 7.8740.05110
Siemens 3RT2926-1CD00 3RT2926-1CD00 3RT2926-1CD00
Circuit breaker -F11 7.8742.01120 7.8742.01120 7.8742.01120
3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10
1,4-2 A 1,4-2 A 1,4-2 A
Siemens setting: 1,4 A setting: 1,4 A setting: 1,4 A
Transformer -T11 7.2239.20070 7.2239.20070 7.2239.20070
USTE400 / 2x 115 V USTE400 / 2x 115 V USTE400 / 2x 115 V
Block 400 VA 400 VA 400 VA
cables
motor cable -W211 9YSLCY 9YSLCY 9YSLCY
Ursprung:
4x10 mm² 4x10 mm² 4x10 mm²
screened screened screened
Tape-wound core -R3 7.8538.0 7.8538.0 7.8538.0
Magnetec M112 M112 M112
power wiring -W280 H07V-K H07V-K H07V-K
3x1x16 mm² 3x1x16 mm² 3x1x16 mm²
black black black
Ferrit bead -R2 7.3140.03500 7.3140.03500 7.3140.03500
Ersatz für:
Schaffner RU35892 RU35892 RU35892
Ersatz durch:
26.07.2018
Geiger
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

901748 14 E ASK SFC 111
13 Annex
4
Bl.
5
page
model ASK 40 SFC
machine power supply 380 V ±10 %, 60 Hz 400 V ±10 %, 50 Hz 440 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz
UASK.F-03067.02
Control voltage 230 V 230 V 230 V 230 V
=
+
Motor -M1 22 kW 22 kW 22 kW 22 kW
Motor -M4 0,55 kW 0,55 kW 0,55 kW 0,55 kW
supply connection fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12
PE rail Torque 10 Nm 10 Nm 10 Nm 10 Nm
Terminal strip -X0 3x 895314.0 3x 895314.0 3x 895314.0 3x 895314.0
Wago 285-150 285-150 285-150 285-150
Stripped length X 30 mm 30 mm 30 mm 30 mm
Handling fig. 2, Sht. 12 fig. 2, Sht. 12 fig. 2, Sht. 12 fig. 2, Sht. 12
Frequency converter -T1 7.8833.01140 7.8833.01140 7.8833.01140 7.8833.01130
6SL3210-1PE26-0AL0 6SL3210-1PE26-0AL0 6SL3210-1PE26-0AL0 6SL3210-1PE24-5AL0
SC2 MCS
30 kW, 380 V-480 V 30 kW, 380 V-480 V 30 kW, 380 V-480 V 22 kW, 380 V-480 V
Control Unit 7.7830.00710 7.7830.00710 7.7830.00710 7.7830.00710
Siemens 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1
Circuit breaker -F4 7.8742.01120 7.8742.01120 7.8742.01120 7.8742.01120
3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10
1,4-2 A 1,4-2 A 1,4-2 A 1,4-2 A
setting: 1,9 A setting: 1,5 A setting: 1,7 A setting: 1,6 A
Auxiliary switch 7.8742.05000 7.8742.05000 7.8742.05000 7.8742.05000
Siemens 3RV2901-1E 3RV2901-1E 3RV2901-1E 3RV2901-1E
Contactor -Q4 7.8740.00040 7.8740.00040 7.8740.00040 7.8740.00040
Compressor ASK SFC

3RT2023-1AL20 3RT2023-1AL20 3RT2023-1AL20 3RT2023-1AL20
Interference suppressor 7.8740.05110 7.8740.05110 7.8740.05110 7.8740.05110
Siemens 3RT2926-1CD00 3RT2926-1CD00 3RT2926-1CD00 3RT2926-1CD00

Circuit breaker -F11 7.8742.01120 7.8742.01120 7.8742.01120 7.8742.01120
3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10 3RV2021-1BA10
1,4-2 A 1,4-2 A 1,4-2 A 1,4-2 A
Siemens setting: 1,4 A setting: 1,4 A setting: 1,4 A setting: 1,4 A
Transformer -T11 7.2239.20070 7.2239.20070 7.2239.20070 7.2239.20070
USTE400 / 2x 115 V USTE400 / 2x 115 V USTE400 / 2x 115 V USTE400 / 2x 115 V
Block 400 VA 400 VA 400 VA 400 VA
cables
motor cable -W211 9YSLCY 9YSLCY 9YSLCY 9YSLCY
4x16 mm² 4x16 mm² 4x16 mm² 4x16 mm²
screened screened screened screened
Ursprung:
Tape-wound core -R3 7.8538.0 7.8538.0 7.8538.0 7.8538.0
Magnetec M112 M112 M112 M112
power wiring -W280 H07V-K H07V-K H07V-K H07V-K
3x1x16 mm² 3x1x16 mm² 3x1x16 mm² 3x1x16 mm²
black black black black
Ferrit bead -R2 7.3140.03500 7.3140.03500 7.3140.03500 7.3140.03500
Schaffner RU35892 RU35892 RU35892 RU35892
Ersatz für:
Ersatz durch:
26.07.2018
Geiger
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

112 ASK SFC 901748 14 E
13 Annex
5
Common parts
Bl.
5
page
model ASK.3 SFC
machine power supply 380 V ±10 %, 60 Hz
400 V ±10 %, 50 Hz
UASK.F-03067.02
440 V ±10 %, 60 Hz
=
+
460 V ±10 %, 60 Hz
Control voltage 230 V

Terminal strip -X2/ -X11 7.6836.00620 Wieland
Handling fig. 1, Sht. 12
Coupling relay -K53, -K54, -K55 3x 7.3149.00660
Wieland FLARE-24DC-1W-250V6A
Power supply -T21 7.7605P0
Prodrive PSDC24/2.5
Compressor control -K20 7.7601.0
SC2 MCS
Prodrive SIGMA CONTROL 2 MCS
IO-module -K21 7.7602.1
Prodrive SIGMA CONTROL 2 IOM-1
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV
7.3218.0 / MTHOO
Switching element Schlegel 7.3219.0 / MTO
Control cabinet ventilator -M7.1 7.2751.00560
Rübsamen&Herr LV550 230 V, 50/60 Hz grey
Control cabinet ventilator -M7.2 7.2751.00031
Rübsamen&Herr LV200 230 V, 50/60 Hz grey
Compressor ASK SFC

Outlet filter 7.2752.00090
GV400 / yellow
7.2752.00020

Rübsamen&Herr GV200 / grey
Control cabinet KAESER 7.8705.00010
Mounting plate KAESER 214411.00020
Ursprung:
Ersatz für:
Ersatz durch:
26.07.2018
Geiger
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

901748 14 E ASK SFC 113
114
1 2 3 4 5 6 7 8
-X0 U1 -X0 U1 L1
/2.1
**** V1 V1 L2
/2.1
W1 W1 L3
/2.1
PE
/2.1
Feed line connection NSGAFöu,
see page 12 2,5mm² black
short circuit proof
13
13.3
ASK SFC
-R2
**** 16mm² green/yellow
Operating Manual
-W280 500V 70°C
Annex
****
PE rail
L1 / U1
L2 / V1
L3 / W1
PE
DCN
DCP
F3
R2
R1
-T1
Electrical Diagram
4mm² green/yellow AC
500V 70°C DC SINAMICS
/7.2 T1.0
1 0 G120
-X11 PE3 STO_A
STO_B

DC
AC STO_A STO_B
PE rail
0V
0V
PE
24V
24V
V(2)
U(2)
W(2)
-R3
Main switch, **** -T1
Fuse supplied
by user
-W211
10mm² green/yellow **** 4mm² green/yellow 10mm² green/yellow 25mm² green/yellow
500V 70°C 500V 70°C 500V 70°C 500V 70°C
U
V
W
PE
Unit frame Oil separator PE rail Side panel door PE rail Unit frame
L1 L2 L3 PE
M
3~
See operating manual for supply
cable cross-section and fusing -M1 **** performance-related components,
****
s.b.c. = supplied by customer see: Equipment parts list
Function: Compressor motor

Group of functions: Main power supply Power switching
c Datum 26.07.2018 Circuit diagram =
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Power switching SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
L1 L1
901748 14 E
/1.8 /3.1
L2 L2
/1.8 /3.1
L3
/1.8
PE
/1.8
Fan motor contactor activation Control cabinet ventilator
-K21 DOR 1.03 -K21 DOR 1.01
/5.3 COM /5.3 COM
4
6
13
2
4
6
13
21
-F4 -F4 X5 X5
Int. Int.
2
13
14
13.3
14
22
A1
A1
****
3
-K54 -K55
ASK SFC
I>> I>> I>>
Int.
1
3
5
5
A2
A2
11
X3
-K21 DI_PA DI -X2 21 3L-
/7.3
Operating Manual
DI 1.03
Annex
/5.3 14 11 14 11
Overload protection switch 5 12 6 12
2,5mm² black Fan motor
500V 70°C
-X11 4 -X11 5 L011
/3.5
Electrical Diagram
12
14
12
14
-K54 -K55
2
4
6
-Q4 5 6
11
11
5
1
3
5

6
-X11 -X11 7
L1
L1
-X11 PE1 -M7.1 -M7.2

M PE M PE
65/93W 1~ 20W 1~
N
N
GNYE
-W29 4G2,5mm² 230V 230V
500V 70°C -Q4 A1 50/60Hz 50/60Hz
PE1
PE2
A2
-X11 -X11
U1
V1
W1
PE
M -X11 02 -X11 05 -X11 04 L02
/3.1
3~
1 2
2
-M4 3 4
2
**** 5 6
2
13 14
**** performance-related components, 21 22
see: Equipment parts list
Function: Fan motor activation Fan motor activation Control cabinet ventilator
Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Fan motor / Control cabinet ventilator SC2 MCS SASK.F-03067.02 12 Bl.
115
116
1 2 3 4 5 6 7 8
L1
/2.8
L2
/2.8
-X11 2 -X11 1 -X11 3 L01
/4.1
NSGAFöu
2,5mm² black
3L+
short circuit proof /7.3
1
1
-W71 -W73
2
4
6
11
31
21
-F11 -S1
EMERGENCY STOP
13
32
22
13.3
12
1
2
**** -W101
ASK SFC
I>> I>> I>>
1
3
5
2
2
-W71 -W73
Int.
9
8
X3
Operating Manual
Annex
1,5mm² black DI_PA DI

-K21
500V 70°C
/5.3 DI 1.00
EMERGENCY STOP
.
4
L011 -X11
/2.8
Electrical Diagram
2,5mm² green/yellow
500V 70°C
-T11 -K21 DOR COM
-X11 PE2 connection
s.b.c. /5.3 COM
9
8
**** 10VA X5
Int.

230V .
.
model-specific -X2 26
electrical diagram
PE3
-X11
see page 11
L02 -X11 04 -X11 01 -X11 01 L02

/2.8 /4.1
500V 70°C
PE1
-X11
**** performance-related components,
s.b.c. = supplied by customer
Function: 230V/1~/50/60Hz EMERGENCY STOP
Group of functions: Control voltage tapping Consumer external Safety chain
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Control voltage tapping / Safety chain SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
L01 -K20
/3.8
MCS
X5
SD card
500V 70°C
X6
13
13.3
option COM-Module RS485-FC Ethernet IO-Bus

Control cabinet X4 X3 X1 X2
ASK SFC
9 8 7 6 5 4 3 2 1
N P
/7.7 -W81
Operating Manual
BN
Annex
3x2x0,22mm²
WH /7.7
screened
-T21
1)
-K21 X1
Electrical Diagram
100- + -X2 3 2L+ I/O-BUS

/7.1 /5.3 X4
240V~ +
-X11 3 L1 3 L+
-
24V= 2 L-
IOM 1
-X11 03 N - -X2 03 2L-
/7.1 1 FE
2,5A -
short circuit proof I/O-BUS

500V 70°C
1,5mm² green/yellow X2
PE1
-X11
500V 70°C
PE2
-X11
L02
/3.8
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of functions: Control voltage
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Power supply unit SC2 MCS SASK.F-03067.02 12 Bl.
117
118
1 2 3 4 5 6 7 8
-K21 IOM1 internal

11 1
/2.4 DI_PA AII_PA
10 2
DI_PA AII 1.02
X6
9 3
/3.7 DI_PA AII_GND
8
/3.7 DI 1.00
7
13
1
13.3
DI 1.01 AIR 1.03

6
X7
2
X3
DI 1.02 AIR 1.03 -K21
ASK SFC
5
/2.4 DI 1.03
4 IOM1 external
DI 1.04 1
3 DI_PB
DI 1.05
Operating Manual
2
2 DI_PB /6.2 AII 1.00 X11 X22 DI 1.00
Annex
DI 1.06 3
1 DI_PB AII 1.01 X12 X23 DI 1.01
DI 1.07 4
DI_PB AII 1.02 X13 X24 DI 1.02
8 5
DOT 1.01 DI_PB /6.4 AIR 1.00 X14 X25 DI 1.03
7 6
Electrical Diagram
M24 DI_PB AIR 1.01 X15 X26 DI 1.04
X8
6 7
DOT 1.02 DI 1.08 AIR 1.02 X16 X27 DI 1.05
5 8
M24 DI 1.09 AIR 1.03 X17 X28 DI 1.06
X4
4 9
FE DI 1.10 DI 1.08 X18 X29 DI 1.07
3 24V 10
/4.7 L+ DI 1.11 DI 1.09 X19 X30 DOT 1.00 /6.2
2 11

/4.7 0V L- DI 1.12 DI 1.14 X20 X31 DOT 1.01
1 12
/4.7 FE DI 1.13 /6.3 DI 1.15 X21 X32 DOT 1.02
9 1
/3.7 DOR COM DOR 1.05
8 2
DOR COM DOR COM
7 3
/7.6 DOR 1.00
6 4
/2.6 DOR 1.01 DOR 1.06
5 5
/7.7
X9
DOR 1.02 DOR COM
X5
4 6
/2.5 DOR 1.03
3 7
DOR 1.07
2 8
DOR COM DOR COM
1 9
DOR 1.04
Function:
Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: IO-module / Configuration SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
-B1 -B40
P
1
-B2
4...20mA
P Pt100
2
- +
>1,0 bar
2
1
1
4
13
13.3
-W115 -W104 -W117
ASK SFC
Operating Manual
Ext. Ext. Ext.
Annex
1
2
3
1
2
3
1
2
3
X11 X21 X14
-K21 AII AII_PA GND -K21 DI_PB DI -K21 AIR_A Shield AIR_B
/5.3 AII 1.00 /5.3 DI 1.15 /5.3 AIR 1.00

Electrical Diagram
Air main pressure Direction of rotation Airend discharge temperature

Control valve
-K21 DOT 1.00
/5.3 DOT M24
1
2
3
X30
Ext.
-W113
1(+)
2(-)
1
2
-K1
Function:
Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: sensors / actuators SC2 MCS SASK.F-03067.02 12 Bl.
119
120
1 2 3 4 5 6 7 8
STO STO
Channel 1 Channel 2
-K21 DOR 1.00 -K21 DOR 1.02
/5.3 COM /5.3 COM
-X2 20
7
5
3L+ X5 X5
/3.8
Int. Int.
3L-
/2.8
-X2 PE1 -X2 25 21 23 22 24
13
13.3
screen rail
ASK SFC
6
3
4
5
2
1
ESC OK -W160 7G0,75mm²
ÖLFLEX 150CY
Operating Manual
/4.7 BN
Annex
-T1
/4.7 WH
1
2
3
4
34
10
11
9
28
69
5
6
7
8
16
17
-T1
+10 V 0 V AI0+ AI0- DI AI1+ AI1- U24V GND DI DI0 DI1 DI2 DI3 DI4 DI5
OUT COM2 COM1
ON
OFF
RDY 64 7
Electrical Diagram
Frequency converter AI 0/1 5

32 6 4
16 5 3
1 2
/1.5 SINAMICS CU240E-2 BF 8 4 2
4 3
RS-485
T1.0 1
I U motor running 2 2
BUS ADDRESS
SAFE 1 1
-W255 LiYCY
IN 0,5A 0 - 20 mA PTC/KTY Bus termination
2x0,23mm²
+24V 0V AO0+ AO0- + - AO1+ AO1- NC NO COM NO COM NC NO COM -T1

31
32
12
13
14
15
26
27
18
19
20
21
22
23
24
25
2
1
-W162 3G0,75mm² -T1

ÖLFLEX 150CY
2L+ -X2 2 -X2 1
/4.5
4
-X2
A1
screen rail
-K53
A2
2L- -X2 02 -X2 04 -X2 01

/4.5
14 11
/8.4 12
Function: Volt-free contacts

Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Binary inputs / outputs FC SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
13
13.3
Volt-free contacts
User's connection
ASK SFC
Operating Manual
Annex
14
12
-K53
/7.5
11
Electrical Diagram
15
16
17
-X11 -X11 -X11

max. 250V AC/6A
24V DC/2A
All non-designated conductors

1,5mm² orange 500V 70°C
Function: Compressor motor running

Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Volt-free contacts SC2 MCS SASK.F-03067.02 12 Bl.
121
122
1 2 3 4 5 6 7 8
Possible connections for AII 1.02
** Pre-allocated Inputs/outputs for use by others 4-wire connection

*** Available for use 2-wire connection
Example connections L+ L-
?
?
4...20mA 4...20mA
Pt100
out - + -
13
13.3
ASK SFC
Operating Manual
Annex
Int. Int. Int.
1
2
3
1
2
3
1
2
Int. Int. Int. Int. Int. X6 X6 X7
4
3
2
1
11
X3 X3 X3 X3 X3 -K21 AII_PA AII GND -K21 AII_PA AII GND -K21 AIR_A AIR_B
-K21 -K21 -K21 -K21 -K21
AII 1.02 AII 1.02 AIR 1.03
Electrical Diagram
DI_PA DI 1.04 DI 1.05 DI 1.06 DI 1.07

4-20mA 4-20mA, 18V DC Pt100
*** *** *** *** Ri = 200Ω Ri = 200Ω
analog inputs, User's connection

max. cable length 30m

Int. Int. Int. Int. Int. Int.
1
7
2
8
3
9
4
5
6
10
11
12
X8 X8 X8 X8 X8 X8
-K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI
DI 1.08 DI 1.09 DI 1.10 DI 1.11 DI 1.12 DI 1.13
*** *** *** *** Remote ON/OFF ** load/idling **
digital inputs, User's connection

18V DC/7mA
Function:
Group of functions: digital inputs analog inputs
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: inputs SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
Inputs/outputs for use by others
Digital output, User's connection Digital output, User's connection

max. 250V AC/24V DC, 1A 24V DC/0,3A
13
13.3
max. cable length 100m max. cable length 30m
ASK SFC
*** Control ON ** ALARM ** Compressor motor running ** *** ***
-K21 DOR 1.04 -K21 DOR 1.05 -K21 DOR 1.06 -K21 DOR 1.07 -K21 DOT 1.01 -K21 DOT 1.02
Operating Manual
DOT M24 DOT M24
8
6
Annex
2
1
2
1
5
4
8
7
7
5
X5 X9 X9 X9 X4 X4
Electrical Diagram

** Pre-allocated
*** Available for use
Function:
Group of functions: digital outputs
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: digital outputs SC2 MCS SASK.F-03067.02 12 Bl.
123
124
1 2 3 4 5 6 7 8
diagram 1
primary
L1
L2
-T11 Power connection 1-2
1
31
32
33
34
35
36
37
38
2
-X11 PE2 Jumper
primary between:
460V 32-36
440V 32-37
0
0
13
400V 32-38
115V
115V
13.3
380V 31-38
ASK SFC
L02
-F11:5
230V
secondary
Operating Manual
Annex
Electrical Diagram

a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: transformer diagrams SC2 MCS SASK.F-03067.02 12 Bl.
901748 14 E
1 2 3 4 5 6 7 8
901748 14 E
fig. 1: Handling: Control line terminal fig. 10: Feed line connection
13
13.3
ASK SFC
Operating Manual
Annex
Electrical Diagram
fig. 2: Handling: Supply terminal Wago

a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Handling: Terminals / Feed line connection SC2 MCS SASK.F-03067.02 12 Bl.
125
126
** See operating manual for **** performance-related components,
supply cable cross-section see: Equipment parts list
13
13.3
ASK SFC
-s.b.c. **
Cable identification
-W255 LiYCY 2x0,23mm²
-W211 ****
-W162 3G0,75mm² ÖLFLEX 150CY
Operating Manual
Annex
-W160 7G0,75mm² ÖLFLEX 150CY

-W73 2x1mm² 500V 70°C 1 2
-
7
5
+
31
32
A2
A1
A2
Connection number
Electrical Diagram
external
Destination
Component identification
-T1
-T1
-T1
-T1
screen rail
screen rail
supply
supply
supply
-K53
-T21
-T21
-K53
-S1
-K54
-K21-X5
-K21-X5
-S1
Location

/7.6
/7.6
/7.7
/1.4
/7.6
/7.7
/1.4
/1.4
/1.4
/1.4
/1.4
/1.5
/7.6
/7.5
/7.2
/7.2
/4.4
/4.4
/7.5
/7.4
/7.5
/2.5
/7.6
/7.5
/7.6
/7.4
/3.6
/3.6
/7.3
Wire link
Terminal legend
total 4 Terminals
total 2 Terminals
total 6 Terminals
total 17 Terminals
Terminal strip
Link
Terminal strip: -X0

Terminal strip: -X2
Terminal number
Terminal strip: -screen rail
SES
SES
SES
SES
SES
SES
U1
U1
V1
V1
W1
W1
1
01
2
02
3
03
4
04
20
21
22
23
24
25
26
27
PE1
Terminal strip: -screen rail FC

2
4
6
9
9
25
24
28
16
69
17
34
Connection number
L2 / V1
L1 / U1
L3 / W1
internal
Destination
-T1
-F4
-T1
-F4
-T1
-F4
-T1
-T1
-T1
-T1
-T1
-T1
-T1
-T1
-K21-X5
-W160 7G0,75mm² ÖLFLEX 150CY 3 4 2 5 1 6

-W162 3G0,75mm² ÖLFLEX 150CY 1 2
-W280 ****
c Datum 26.07.2018 Terminal schedule =
a Geprüft Geiger
H Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: screen rail/- FC, Terminal strip -X0,-X2 SC2 MCS KASK.F-03067.02 2 Bl.
901748 14 E
Volt-free contacts GNYE = green/yellow
901748 14 E
4) Compressor motor running
13
2,5mm² green/yellow 500V 70°C

13.3
ASK SFC
-W71 2x1mm² 500V 70°C 1 2
4)
4)
4)
N
N
11
12
L1
L1
PE
PE
Operating Manual
Connection number
Annex
external
Destination
s.b.c.
s.b.c.
-S1
-S1
-M7.2
-M7.1
-M7.1
-M7.2
-M7.1
-K21-X4
-M7.2
-T21
s.b.c.
Electrical Diagram
Location
/3.4
/3.2
/3.3
/2.5
/3.6
/4.2
/2.5
/3.2
/2.6
/2.6
/2.6
/2.7
/2.3
/3.2
/2.7
/4.3
/3.4
/8.4
/8.4
/8.5
Wire link
Terminal legend

Terminal strip
Link
total 20 Terminals
Terminal number
1
01
2
02
3
03
4
04
5
05
6
7
PE1
PE1
PE2
PE2
PE3
15
16
17
Terminal strip: -X11

.
.
0
6
N
L1
14
14
11
11
12
14
A2
PE
PE
Connection number
internal
Destination
-T11
-F11
-Q4
-T21
-T21
-K54
-K55
-K55
-M4
-T11
PE rail
-K53
-K53
-K53
-W29 4G2,5mm² 500V 70°C GN
YE
4mm² green/yellow 500V 70°C
a Geprüft Geiger
H Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Terminal strip -X11 SC2 MCS KASK.F-03067.02 2 Bl.
127
128
1 2 3 4 5 6 7 8
13
13.3
ASK SFC
1270
230V
Operating Manual
Annex
W1
-T11
-X0
V1
-F4
U1
230V
Electrical Diagram
-T21
-F11
24V
PE rail
230V
24V
230V
470
-X11

-K53
-K54
-K55
24V
24V
-T1
-X2
-Q4
The components are performance-related
and not shown to scale.
230V
24V
c Datum 26.07.2018 Component layout =

a Geprüft Geiger
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Switchboard SC2 MCS AASK.F-03067.02 1 Bl.
901748 14 E
Operating Manual
SK SFC
9_9463 22 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com
Original instructions
/KKW/SSK 2.22 en SBA-SCHRAUBEN-SFC-SC2
/KKW/SSC 2.08
20190705 081755
Contents

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alert notes and their symbols .................................................................... 2
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Mass ................................................................................................................................. 5
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 6
2.8 Flow rate (constant delivery volume relative to intake conditions) ................................... 7
2.9 Cooling oil recommendation ............................................................................................. 11
2.10 Cooling oil charge ............................................................................................................ 12
2.11 Motors and power ............................................................................................................ 13
2.12 Noise emission [dB(A)] ..................................................................................................... 13
2.13 Electrical connection ........................................................................................................ 13
2.14 Power supply specifications ............................................................................................. 14
2.14.1 Earthed conductor specification .......................................................................... 14
2.15 Available heat capacity .................................................................................................... 16
3.2 Specified use .................................................................................................................... 17
3.3 Improper use .................................................................................................................... 17
3.4 User's responsibilities ....................................................................................................... 17
3.4.1 Observe statutory and universally accepted regulations .................................... 17
3.4.2 Determining personnel ........................................................................................ 18
3.4.3 Complying with Inspection Schedules and Accident Prevention Regulations .... 18
3.5 Dangers ............................................................................................................................ 19
3.5.1 Safely dealing with sources of danger ................................................................ 19
3.5.2 Safe machine operation ...................................................................................... 21
3.5.3 Organisational Measures .................................................................................... 23
3.5.4 Danger Areas ...................................................................................................... 23
3.6 Safety devices .................................................................................................................. 24
3.7 Service life of safety functions .......................................................................................... 24
3.8 Safety signs ...................................................................................................................... 25
3.9 Emergency situations ....................................................................................................... 26
3.9.1 Correct fire fighting ............................................................................................. 26
3.9.2 Treating injuries from handling cooling oil .......................................................... 27
3.10 Warranty ........................................................................................................................... 27
3.11 Environment protection .................................................................................................... 28
4.1 Enclosure ......................................................................................................................... 29

9_9463 22 E SK SFC i
Contents
4.2 Machine function .............................................................................................................. 30

4.2.1 Frequency Converter .......................................................................................... 30
4.2.2 Safety devices .................................................................................................... 31
4.2.3 Floating relay contacts ........................................................................................ 31
4.3 Operating panel SIGMA CONTROL 2 ............................................................................. 31
4.4 Operating modes and control modes ............................................................................... 34
4.4.1 Machine operating modes .................................................................................. 34
4.4.2 Control modes .................................................................................................... 35
4.4.3 Variable speed drive with frequency converter (SFC) ........................................ 36
4.5 Options ............................................................................................................................. 36
4.5.1 SIGMA CONTROL 2 controller: Connection to control technology .................... 36
4.5.2 Machine mountings ............................................................................................. 37
4.5.3 Prepared for external heat recovery ................................................................... 37
5.1 Ensuring safety ................................................................................................................ 38
5.2 Installation conditions ....................................................................................................... 38
5.2.1 Determining location and clearances .................................................................. 38
5.2.2 Ensuring the machine room ventilation ............................................................... 39
5.2.3 Exhaust duct design ........................................................................................... 40
5.3 Operating the machine in a compressed air network ....................................................... 40
6 Installation
6.1 Ensuring safety ................................................................................................................ 41
6.2 Reporting Transport Damage ........................................................................................... 42
6.3 Connecting the machine with the compressed air network .............................................. 42
6.4 Connecting the external pressure transducer .................................................................. 43
6.5 Connecting the machine to the power supply .................................................................. 43
6.6 Options ............................................................................................................................. 44
6.6.1 Anchoring the machine ....................................................................................... 44
6.6.2 Connecting the external heat recovery system ................................................... 44
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 45
7.2 Instructions to be observed before commissioning .......................................................... 46
7.3 Checking installation and operating conditions ................................................................ 46
7.4 Commissioning the Frequency Converter ........................................................................ 47
7.5 Pouring cooling oil into the airend .................................................................................... 47
7.6 Starting the machine for the first time .............................................................................. 48
7.7 Checking the door interlock switch ................................................................................... 48
7.8 Setting the set point pressure .......................................................................................... 49
7.9 Setting the display language ............................................................................................ 49
8 Operation
8.1 Switching on and off ......................................................................................................... 51
8.1.1 Switching on ....................................................................................................... 51
8.1.2 Switching off ....................................................................................................... 51
8.2 Switching off in an emergency and switching on again .................................................... 52
8.3 Using the remote control for switching on and off ............................................................ 52
8.4 Using the timer for switching on and off ........................................................................... 53
8.5 Interpreting operation messages ...................................................................................... 54
8.6 Acknowledging alarm and warning messages ................................................................. 54
9.2 Other faults ....................................................................................................................... 56

ii SK SFC 9_9463 22 E
Contents
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 58
10.2 Following the maintenance plan ....................................................................................... 59
10.2.1 Logging maintenance work ................................................................................. 59
10.2.2 Resetting maintenance interval counters ............................................................ 59
10.2.3 Regular maintenance tasks ................................................................................ 60
10.2.4 Cooling oil Change interval ................................................................................. 61
10.2.5 Regular service tasks ......................................................................................... 61
10.3 Cooler: Cleaning or Renewing the Filter Mats ................................................................. 62
10.4 Control cabinet: Clean or renew the filter mat .................................................................. 63
10.5 Cooler maintenance ......................................................................................................... 63
10.6 Maintaining the external heat recovery system ................................................................ 65
10.7 Air Filter Maintenance ...................................................................................................... 65
10.8 Compressor motor maintenance ...................................................................................... 66
10.9 Drive belt maintenance .................................................................................................... 66
10.10 Testing the pressure relief valve ...................................................................................... 67
10.11 Check the safety shut-down due to excessive airend discharge temperature. ................ 68
10.12 Check the EMERGENCY STOP control device ............................................................... 68
10.13 Checking the cooling oil level ........................................................................................... 68
10.14 Venting the machine (de-pressurising) ............................................................................ 69
10.15 Replenish cooling oil ........................................................................................................ 71
10.15.1 Venting the machine (de-pressurising) ............................................................... 72
10.15.2 Topping up with cooling oil and trial run ............................................................. 72
10.16 Changing the cooling oil ................................................................................................... 73
10.17 Changing the oil filter ....................................................................................................... 77
10.18 Changing the oil separator cartridge ................................................................................ 78
10.19 Documenting maintenance and service work .................................................................. 81
11.1 Note the nameplate .......................................................................................................... 82
11.2 Ordering consumable parts and operating fluids/materials .............................................. 82
11.3 KAESER AIR SERVICE ................................................................................................... 82
11.4 Replacement parts for service and repair ........................................................................ 83
12.1 De-commissioning ............................................................................................................ 86
12.1.1 Temporary de-commissioning ............................................................................ 86
12.1.2 Long-term de-commissioning ............................................................................. 86
12.2 Packing ............................................................................................................................ 87
12.3 Storage ............................................................................................................................. 87
12.4 Transport .......................................................................................................................... 87
12.4.1 Safety .................................................................................................................. 87
12.4.2 Transport with a forklift truck ............................................................................... 87
12.4.3 Transport with a hoist ......................................................................................... 88
12.5 Disposal ........................................................................................................................... 90
12.5.1 Battery disposal in accordance with local environmental regulations. ................ 90
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 91
13.2 Dimensional drawing ........................................................................................................ 97
13.3 Electrical Diagram ............................................................................................................ 100

9_9463 22 E SK SFC iii
Contents

iv SK SFC 9_9463 22 E
Fig. 1 Maximum relative humidity of intake air ..................................................................................... 6

Fig. 2 Flow rate and regulating range ................................................................................................... 8
Fig. 3 Location of safety signs .............................................................................................................. 25
Fig. 4 Enclosure overview .................................................................................................................... 29
Fig. 5 Machine layout ........................................................................................................................... 30
Fig. 6 Keys – overview ......................................................................................................................... 31
Fig. 7 Indicators – overview .................................................................................................................. 32
Fig. 8 RFID reader ................................................................................................................................ 33
Fig. 9 Machine mountings .................................................................................................................... 37
Fig. 10 Recommended machine placement and dimensions [mm] ........................................................ 39
Fig. 11 Compressed air pipework ........................................................................................................... 42
Fig. 12 Charging hole ............................................................................................................................. 48
Fig. 13 Position of the door interlock switch ........................................................................................... 49
Fig. 14 Switching on and off ................................................................................................................... 51
Fig. 15 Switching off in an emergency ................................................................................................... 52
Fig. 16 Using the remote control for switching on and off ...................................................................... 53
Fig. 17 Using the timer for switching on and off ..................................................................................... 54
Fig. 18 Acknowledging messages .......................................................................................................... 55
Fig. 20 Switching cabinet ventilation ...................................................................................................... 63
Fig. 22 Air filter maintenance .................................................................................................................. 65
Fig. 23 Drive belt maintenance ............................................................................................................... 66
Fig. 24 Check the EMERGENCY STOP control device ......................................................................... 68
Fig. 25 Checking the cooling oil level ..................................................................................................... 69
Fig. 26 Venting the machine ................................................................................................................... 70
Fig. 27 Replenish cooling oil .................................................................................................................. 71
Fig. 28 Changing the cooling oil, oil separator tank ............................................................................... 74
Fig. 29 Changing the cooling oil Oil cooler ............................................................................................. 75
Fig. 30 Changing the cooling oil, heat recovery system ......................................................................... 76
Fig. 31 Changing the oil filter .................................................................................................................. 77
Fig. 32 Changing the oil separator cartridge .......................................................................................... 79
Fig. 33 Transporting with a forklift truck ................................................................................................. 88
Fig. 34 Transporting with a crane ........................................................................................................... 89
Fig. 35 Battery labelling .......................................................................................................................... 90

9_9463 22 E SK SFC v

vi SK SFC 9_9463 22 E
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Mass ........................................................................................................................................... 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 10 Pressure relief valve activating pressure (50 Hz) ....................................................................... 7
Tab. 11 Pressure relief valve activating pressure (60Hz) ........................................................................ 7
Tab. 21 Cooling oil recommendation ....................................................................................................... 11
Tab. 22 Cooling oil recommendation (food processing) .......................................................................... 12
Tab. 23 Cooling oil recommendation (machines for snow cannons) ....................................................... 12
Tab. 24 Cooling oil charge (Option K1) ................................................................................................... 13
Tab. 25 Cooling oil charge (Option W1) .................................................................................................. 13
Tab. 26 Compressor drive motor ............................................................................................................. 13
Tab. 27 Noise emission [dB(A)] ............................................................................................................... 13
Tab. 28 Earthed conductor specification ................................................................................................. 15
Tab. 33 Heat capacity (Option W1) ......................................................................................................... 16
Tab. 34 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 19
Tab. 35 Danger Areas ............................................................................................................................. 24
Tab. 36 Category and Performance Level ............................................................................................... 24
Tab. 37 Safety signs ................................................................................................................................ 25
Tab. 38 Keys ........................................................................................................................................... 32
Tab. 39 LEDs ........................................................................................................................................... 33
Tab. 40 RFID reader ................................................................................................................................ 34
Tab. 41 Energy-efficient control modes ................................................................................................... 35
Tab. 42 Components ............................................................................................................................... 36
Tab. 43 Re-commissioning after storage/standstill .................................................................................. 46
Tab. 44 Installation conditions checklist .................................................................................................. 46
Tab. 46 Remote control identification ...................................................................................................... 53
Tab. 48 Other faults and remedies .......................................................................................................... 56
Tab. 49 Advise others that the machine is being serviced. ..................................................................... 58
Tab. 50 Regular maintenance tasks ........................................................................................................ 60
Tab. 51 Cooling oil Change intervals ....................................................................................................... 61
Tab. 52 Regular service tasks ................................................................................................................. 62
Tab. 53 Permissible cooling oil level under LOAD .................................................................................. 69
Tab. 54 Logged maintenance tasks ........................................................................................................ 81

9_9463 22 E SK SFC vii
List of Tables
Tab. 55 Consumable parts ...................................................................................................................... 82

viii SK SFC 9_9463 22 E

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

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

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

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warnings indicate risks potentially resulting in personal injury, if the measures specified are not
taken.
Warning notices indicate three levels of danger identified by the corresponding signal word:
DANGER Warns of an imminent danger Will very likely result in death or severe injury
WARNING Warns of a potentially imminent dan‐ May result in death or severe injury
ger
CAUTION Warns of a potentially dangerous sit‐ May result in a moderate physical injury
uation
Tab. 1 Danger levels and their definition (personal injury)

9_9463 22 E SK SFC 1
Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐
tions.
Example:
DANGER
The word "DANGER" indicates that death or severe injury can very likely result from ignoring
the warning.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The word "WARNING" indicates that death or severe injury may result from ignoring the warn‐
ing.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Damage warnings have only one danger level, identified with this signal word:
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alert notes and their symbols

This symbol indicates particular important information.

2 SK SFC 9_9463 22 E
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
Option H1 ➤ This symbol is placed by lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with bolt-down machine feet). Option codes used in this
operating manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.

9_9463 22 E SK SFC 3
2.1 Nameplate
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine at one of these positions:
■ Above the cooler
■ On the rear side of the machine
➤ Enter here the nameplate data as a reference:
Characteristic Value
Material No.
Serial No.
Ambient temperature
Rated power
Maximum working pressure PS
Rated motor speed
Phases
Voltage
Full load current
Electrical diagram
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options. The options for this machine are shown near the
nameplate.
➤ Enter options here as a reference:
Option Option code Available?

SIGMA CONTROL 2 C3 ✓
(Prepared for connection to control centre)
IT 3-phase supply C35 —
SIGMA CONTROL 2 C48 —
(Connection to control technology not provided)
KAESER FILTER KE F1 —
Bolt-down machine mounts H1
Air-cooling K1 ✓
Transformer power supply for refrigeration dryer T2 —
Provided: ✓
Not available: —

4 SK SFC 9_9463 22 E
2.3 Mass
Option Option code Available?

Prepared for heat recovery W1
Provided: ✓
Not available: —
Tab. 4 Options
2.3 Mass
The values shown are maximum values. Actual mass of individual machines are dependent on
equipment fitted.
SK 22 SK 25 —
Mass [kg] 329 337 —
Tab. 5 Mass
2.4 Temperature
SK 22 SK 25 —
Minimum cut-in tempera‐ 3 3 —
ture [°C]
Typical airend discharge 65 – 100 65 – 100 —
temperature during oper‐
ation [°C]
Maximum airend dis‐ 110 110 —
charge temperature (au‐
tomatic safety shut-down)
[°C]
Tab. 6 Temperature
2.5 Ambient conditions

SK 22 SK 25 —
Maximum elevation amsl 1000 1000 —
[m]
Permissible ambient tem‐ 3 – 45 3 – 45 —
perature [°C]
Cooling air temperature 3 – 45 3 – 45 —
[°C]
Intake air temperature 3 – 45 3 – 45 —
[°C]
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions

9_9463 22 E SK SFC 5
2.6 Ventilation
Fig. 1 Maximum relative humidity of intake air

T Intake air temperature [°C]
H Maximum relative humidity of intake air [%]
2.6 Ventilation
The values given are minimum guide values.
SK 22 SK 25 —
Inlet aperture Z see fig‐ 0.35 0.40 —
ure 10 [m2]
Forced ventilation with 4700 5700 —
exhaust fan:
Pa
SK 22 SK 25 —
Inlet aperture Z see fig‐ 0.35 0.40 —
ure 10 [m2]
Forced ventilation with 4700 5700 —
exhaust fan:
Pa
2.7 Pressure
See nameplate for maximum working pressure

6 SK SFC 9_9463 22 E
Maximum working over‐ SK 22 SK 25 —

pressure [bar]
8.0 10 10 —
11.0 13 13 —
15.0 16* 16* —*
* China: 15.9
Tab. 10 Pressure relief valve activating pressure (50 Hz)
Maximum working over‐ SK 22 SK 25 —

pressure [bar]
8.5 10 10 —
11.0 13 13 —
15.0 16 16 —
Tab. 11 Pressure relief valve activating pressure (60Hz)

Fig. 2 indicates the regulating range of the flow rate 1 , dependant on all current pressure condi‐
tions at the compressed air outlet of the machine (local network pressure pNloc).

9_9463 22 E SK SFC 7
Fig. 2 Flow rate and regulating range

1 Q 6 pAmax
Flow rate Maximum selectable set-point pressure
2 Qmax 7 p
Maximum flow rate (pNloc) Pressure
3 Qmin 8 Qmin (p)
Minimum flow rate (pNloc) Minimum flow rate
4 pAmin 9 Qmax (p)
Minimum selectable system set-point Maximum flow rate
pressure (parameter-dependent)
5 pNloc
Local network pressure at the compressed
air outlet

pNloc [bar] SK 22 SK 25 —
pAmin 0.63 2.12 0.82 2.70 — —
6.0 0.63 2.12 0.82 2.70 — —
7.0 0.62 2.03 0.81 2.60 — —
8.0 (pAmax) 0.61 1.93 0.80 2.50 — —
pAmin 0.64 1.78 0.86 2.43 — —
9.0 0.64 1.78 0.85 2.37 — —

8 SK SFC 9_9463 22 E
10.0 0.63 1.67 0.84 2.25 — —
11.0 (pAmax) 0.61 1.57 0.83 2.13 — —
pAmin 0.59 1.44 0.84 2.00 — —
12.0 0.59 1.44 0.84 2.00 — —
13.0 0.57 1.37 0.83 1.90 — —
14.0 0.55 1.31 0.81 1.81 — —
15.0 (pAmax) 0.53 1.24 0.80 1.71 — —

pAmin 0.63 2.02 0.82 2.57 — —
6.0 0.63 2.02 0.82 2.57 — —
7.5 0.62 1.89 0.81 2.43 — —
8.5 (pAmax) 0.61 1.80 0.80 2.33 — —
pAmin 0.64 1.69 0.85 2.24 — —
9.0 0.64 1.69 0.85 2.24 — —
10.0 0.63 1.61 0.84 2.13 — —

9_9463 22 E SK SFC 9
11.0 (pAmax) 0.61 1.52 0.83 2.02 — —
pAmin 0.59 1.37 0.84 1.89 — —
12.0 0.59 1.37 0.84 1.89 — —
13.0 0.57 1.30 0.83 1.80 — —
14.0 0.55 1.24 0.81 1.71 — —
15.0 (pAmax) 0.53 1.17 0.80 1.62 — —

pAmin 0.63 2.30 0.82 2.88 — —
6.0 0.63 2.30 0.82 2.88 — —
7.5 0.62 2.14 0.81 2.77 — —
8.5 (pAmax) 0.61 2.04 0.80 2.70 — —
pAmin 0.64 1.94 0.85 2.53 — —
9.0 0.64 1.94 0.85 2.53 — —
10.0 0.63 1.85 0.84 2.44 — —
11.0 (pAmax) 0.61 1.75 0.83 2.35 — —

10 SK SFC 9_9463 22 E
pAmin 0.59 1.57 0.84 2.09 — —
12.0 0.59 1.57 0.84 2.09 — —
13.0 0.57 1.50 0.83 2.04 — —
14.0 0.55 1.43 0.81 1.98 — —
15.0 (pAmax) 0.53 1.36 0.80 1.93 — —

A sticker showing the type of oil used is located near the oil separator tank filler.
For information on ordering cooling oil, please see chapter 11.
Cooling oils for general applications
SIGMA FLUID
MOL S-460 S-570
Description Mineral oil Synthetic oil Synthetic oil
Application Standard oil for all appli‐ Standard oil for all applica‐ Special oil for ambient con‐
cations except in connec‐ tions except in connection ditions with high tempera‐
tion with processing of with processing of food‐ tures and humidity.
foodstuffs. stuffs. Standard oil for all applica‐
Particularly suitable for Particularly suitable for ma‐ tions except in connection
machines with a low duty chines with a high duty cy‐ with foodstuffs.
cycle. cle. Particularly suitable for ma‐
Not suitable for East and chines with a high duty cy‐
South East Asia. cle.
Viscosity at 46 mm2/s 46 mm2/s 53 mm2/s
40°°C (ASTM D445) (ASTM D445) (ASTM D445)
Viscosity at 6.9 mm2/s 7.2 mm2/s 8.0 mm2/s
Flash point 230 °C 251 °C 258 °C
Density at 0.868 g/cm3 0.860 g/cm3 0.869 g/cm3
Pour point: −30 °C −27 °C −54 °C
Tab. 21 Cooling oil recommendation

9_9463 22 E SK SFC 11
2.10 Cooling oil charge
Cooling oils for applications in food processing
SIGMA FLUID
FG-460 FG-680
Description Synthetic oil Synthetic oil
Application Specifically for machines in applica‐ Special oil for ambient conditions with high
tions where the compressed air may temperatures and humidity.
come into contact with foodstuff. Specifically for machines in applications
where the compressed air may come into
contact with foodstuff.
Approval USDA H1, NSF USDA H1, NSF
Approved for applications where Approved for applications where contact
contact with foodstuffs may sporadi‐ with foodstuffs may sporadically or inci‐
cally or incidentally be possible. dentally be possible.
Viscosity at 40° 46 mm2/s (ASTM D445) 68 mm2/s (ASTM D445)

°C
Viscosity at 8.0 mm2/s (ASTM D445) 10.5 mm2/s (ASTM D445)
100 °C
Flash point 246 °C (ASTM D92) 238 °C (ASTM D92)
Density at 0.842 g/cm3 (ASTM D1298) 0.854 g/cm3 (ASTM D1298)
15 °C
Pour point: −39 °C (ASTM D97) −39 °C (ASTM D97)
Tab. 22 Cooling oil recommendation (food processing)
Cooling oils for the operation with snow cannons
SIGMA FLUID
PANOLIN HLP SYNTH 46
Description Saturated synthetic ester with additives (mineral oil free)
Easily biologically degradable as per OECD criteria
Application Specifically designed for machines intended for the operation with snow can‐
nons.
Viscosity at 40°°C 47 mm2/s (ISO 2104)
Viscosity at 8.2 mm2/s (ISO 2104)
100 °C
Flash point 240 °C (ISO 2592)
Density at 15 °C 0.918 g/cm3 (ISO 12185, ISO 3675)
Pour point: -57 °C (ISO 3016)
Tab. 23 Cooling oil recommendation (machines for snow cannons)
2.10 Cooling oil charge

For machines with the Option W1, the volume required additionally for the heat recovery must be
added to the charge.

12 SK SFC 9_9463 22 E
SK 22 SK 25 —
Fluid volume* [litre] 7.0 7.0 —
Topping up volume [litres] 0.3 0.3 —
(minimum–maximum)
* Plus the oil volume of the heat recovery system.
Tab. 24 Cooling oil charge (Option K1)
Option W1 Heat recovery
The additional volume corresponds to the oil volume of the heat exchanger and the connecting
lines:
SK 22 SK 25 —
Additional charge vol‐
ume [l]*
* Enter the volume required by your heat recovery system.
Tab. 25 Cooling oil charge (Option W1)

SK 22 SK 25 —
Rated power [kW] 11 15 —
Enclosure protection IP 55 IP 55 —
Tab. 26 Compressor drive motor

Mains frequency SK 22 SK 25 —
50 Hz 67 68 —
60 Hz 68 69 —
Noise pressure level in operation at maximum gauge working pressure and maximum attainable
speed as per ISO 2151 and the basic standard ISO 9614-2, uncertainty: ±3 dB(A)
Tab. 27 Noise emission [dB(A)]
2.13 Electrical connection

Basic requirements
The machine is designed in accordance with the conditions for an electrical power supply specified
in EN 60204-1 (IEC 60204-1) section 4.3.
If no other conditions are specified by the operator, the thresholds described in this standard must
be adhered to.
It is recommended that the user and the supplier reach an agreement on the basis of EN 60204-1,
Annex B.

9_9463 22 E SK SFC 13
For electrical connection of the machine, a symmetric three-phase supply is necessary.

In a symmetrical three phase supply the phase angles and voltages are all the same.
This machine is designed for the operation in an industrial environment with proprietary supply net‐
work separated from the public supply by a transformer or generator.
Incoming line within the switching cabinet to be as short as possible.
If external sensors or communications lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC connections into the switching cabinet.
This machine may only be supplied from an earthed TN or TT three-phase supply in which
the neutral point is earthed.
The connection to an IT three-phase supply or a three-phase supply with one earthed phase
is not permitted.
Further information The wiring diagram in chapter 13.3 contains further details of the power supply connection.

Supply diameters and fusing (class gG) are selected according to DIN VDE 0100 part 430
(IEC 60364-4-43) and DIN VDE 0298-4:2013-06 if the following conditions are met:
■ multi-core copper conductors at an operating temperature up to 70 °C
■ Cable length <50 m
■ for 30 °C ambient temperature
■ wiring type C: without cable contact
■ Current carrying capacity: Table 3, column 11
(European Harmonisation Directive HD 60364-5-52:2011)
■ Bundled cables: Table 21
─ Single layer on wall or floor
─ Spacing ≥ outside diameter
➤ For other application conditions, check and determine the supply diameters according to
DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider.
Other conditions would include, for example:

■ Higher ambient temperature
■ Other cable installation method
■ Other bundled cables
■ Cable length >50 m
Further information The wiring diagram in chapter 13.3 contains further details of the electrical connection data.
2.14.1 Earthed conductor specification

Due to the leakage currents caused by the anti-interference capacitors of the frequency converter,
a minimum diameter of 10 mm2 is required for the earthed conductor (see EN 60204-1).
Use one of the following options, if the earthed conductor for the supply line is smaller than
10 mm2:
■ Multicore conductor including earthed conductor with a minimum diameter of 10 mm2,
■ A minimum diameter of 10 mm2 for the earthed conductor alone,

14 SK SFC 9_9463 22 E
■ a second earthed conductor with the same diameter as the supply line,
■ automatic deactivation of the supply as soon as the earthed conductor is interrupted.
If the minimum diameter of the earthed conductor must be larger than the diameter of the supply
line, this diameter and the number of earthed conductors that can be connected in the control cabi‐
net is shown. In all other instances, the supply line diameter is sufficiently dimensioned.
SK 22 SK 25 —
Maximum supply cable 10 10 —
diameter [mm2]
Maximum number of 2 2 —
earthed conductors
Tab. 28 Earthed conductor specification

SK 22 SK 25 —
Backup fuse [A] 35 50 —
Supply cable [mm2] 4x10 4x10 —
Current drawn [A] 32 38 —

SK 22 SK 25 —
SK 22 SK 25 —
SK 22 SK 25 —

9_9463 22 E SK SFC 15
2.15 Available heat capacity
SK 22 SK 25 —
Supply cable [mm ] 2 4x10 4x10 —
2.15 Option W1
Available heat capacity
The quality of the heat transfer medium and its required flow rate depend on the type of heat
exchanger used.
Maximum permissible pressure loss in the cooling air circuit: 0.6 bar
Maximum heat capacity SK 22 SK 25 —

available*
[kW] 9.7 12.3 —
[MJ/h] 35 44 —
[kcal/h] 8340 10576 —
* with the thermostatic valve set to open at 80 °C.
Tab. 33 Heat capacity (Option W1)

16 SK SFC 9_9463 22 E

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ impairments to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the operating manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
3.2 Specified use

The machine is intended solely for generating compressed air for industrial use. Any other use is
considered incorrect. The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
➤ Comply with the instructions in this operating manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated.
➤ Do not use compressed air for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated.
3.3 Improper use

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

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

9_9463 22 E SK SFC 17
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.
3.4.2 Determining personnel

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

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

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

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

18 SK SFC 9_9463 22 E
3.5 Dangers
➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in § 16:
Inspection Inspection interval Inspecting authority

Installation and equip‐ Before commissioning Competent person
ment inspection (e. g. KAESER SERVICE technician)
Internal inspection Every 5 years after installation or Competent person
Strength test Every 10 years after installation or Competent person
Tab. 34 Inspection intervals according to Ordinance on Industrial Safety and Health
3.5 Dangers
Basic instructions
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.5.1 Safely dealing with sources of danger

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

9_9463 22 E SK SFC 19
3.5 Dangers

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

20 SK SFC 9_9463 22 E
3.5 Dangers
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

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

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

■ Safety work wear
■ Protective gloves

9_9463 22 E SK SFC 21
3.5 Dangers
■ Safety boots
■ Eye protection
■ Ear protection
Transport
The mass and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Assembly
➤ Use only electrical cables that are suitable and approved for the surroundings and electrical
loads applied.
➤ Never dismantle compressed air pipes until they are fully vented.
➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Installation
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance: explosive or chemically instable gases and vapours,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in the warm exhaust air flow from other machines.

22 SK SFC 9_9463 22 E
3.5 Dangers
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
voltage is present.
➤ Allow the machine to cool down.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Carry out regular inspections:
for visible damages,
of safety installations,
of the EMERGENCY STOP command device,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
De-commissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organisational Measures

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

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

9_9463 22 E SK SFC 23
3.6 Safety devices
Activity Danger area Authorised personnel

Transport Within a 3 m radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 1 m radius of the machine and its sup‐
ply cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Tab. 35 Danger Areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4, section 4.2.2.
3.7 Service life of safety functions

Pursuant to ISO 13849-1:2016 Category and Performance Level (PL) of the machine's safety func‐
tions have been analysed and assessed:
Safety function Category Performance Level
Safety shut-down due to excessive airend discharge 2. 3 b
temperature
EMERGENCY STOP device 1. 3 c
Safety shutdown when opening the machine 1. 3 c
Tab. 36 Category and Performance Level
The safety-relevant components of the safety functions are designed for a working life of20 years.
The working life starts with the commissioning, and is not extended by times during which the ma‐
chine was not in use.
The following components are affected:

■ Resistance thermometer (Pt100 sensor for measuring the compression discharge temperature)
■ EMERGENCY STOP control device
■ Frequency converter
■ Door interlock switch

24 SK SFC 9_9463 22 E
3.8 Safety signs
1. The components of the safety functions must be replaced by KAESER SERVICE after a work‐
ing life of 20 years.
2. Have the KAESER SERVICE check the reliability of the safety functions.
3.8 Safety signs

The illustration shows the location of the safety signs on the machine. The table lists the various
safety signs used and their meanings.
Fig. 3 Location of safety signs
Location Symbol Meaning

Switch off and lock out the power supply isolating device and verify the ab‐
sence of any voltage.
2 Hot surface!
Risk of burns caused by contact with hot components.
➤ Do not touch the surface.
➤ Wear long-sleeved garments (no synthetics such as polyester) and protec‐
tive gloves.
3 Risk of serious injuries (to the hands, in particular) or even severing of extremi‐
ties from rotating components!
➤ Operate the machine only with closed safety guards, access doors and
panels.
➤ Switch off and lock out the power supply isolating device and secure
against unintentional reactivation.

9_9463 22 E SK SFC 25
Location Symbol Meaning

4 Personal injury or damage to the machine due to incorrect operation!
➤ Read and understand the operating manual and all safety information be‐
fore switching on this machine.
Risk of injury caused by automatic machine start!
➤ Switch off and lock out the power supply isolating device and secure
against unintentional reactivation.
5 Risk of fatal injury when dismantling valves (spring-loaded or under pressure)!
➤ Do not open or dismantle valves.
➤ Call an authorised service technician in the event of a fault.
13 Danger to life due to high protective conductor current!
➤ Ensure that the protective conductor is sufficiently dimensioned.
➤ Before starting work on the frequency converter or intermediate circuit ca‐
pacitors, wait at least 5 minutes.
Tab. 37 Safety signs

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

26 SK SFC 9_9463 22 E
3.10 Warranty
Extinguishing substances
➤ Suitable extinguishing media:

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

Eye contact:
Cooling oil can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.
Skin contact:
Cooling oil may irritate after prolonged contact.

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

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

➤ Do not induce vomiting.
➤ Seek medical aid.
3.10 Warranty
This operating manual does not contain any independent warranty commitment. Our general terms
and conditions apply with regard to warranty.
A condition of our warranty is that the machine is used solely for the purpose for which it is inten‐
ded and under the conditions specified.
Due to the multitude of applications for which the machine is suitable, the user is obliged to deter‐
mine its suitability for his specific application.
Furthermore, we do not assume any warranty obligation for damages caused by:
■ the use of unsuitable parts or operating materials,
■ arbitary modifications,
■ incorrect maintenance,
■ incorrect repair.

9_9463 22 E SK SFC 27
Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.

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

28 SK SFC 9_9463 22 E
4.1 Enclosure

4.1 Enclosure
Fig. 4 Enclosure overview

1 Control cabinet door 4 Sight glass: Oil level indicator
2 Latch 5 Sight glass: V-belt tension
3 Panel (removable)
When closed, the enclosure serves various functions:

■ Sound insulation
■ Protection against contact with components
■ Cooling air flow
The enclosure is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ As resting place or storage of any kind of load.
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.

9_9463 22 E SK SFC 29
Fig. 5 Machine layout

1 Inlet valve 6 Control cabinet
2 Minimum pressure/check valve 7 Oil separator tank
3 Compressor motor 8 Air filter
4 Oil filter 9 Oil/air cooler
5 Airend
Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure with‐
in the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve
maintains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pres‐
sure / check valve 2 into the air cooler 9 . The minimum pressure / check valve ensures that there
is always a minimum internal pressure sufficient to maintain cooling oil circulation in the machine.
The aftercooler brings down the compressed air temperature to 5K to 10K above ambient. Most of
the moisture carried in the air is removed in the aftercooler.
4.2.1 Frequency Converter

The converter varies the speed of the drive motor according to the air demand.

30 SK SFC 9_9463 22 E
4.2.2 Safety devices

The following safety devices are provided and must not be modified or disabled.
■ EMERGENCY STOP control device:
Stops the machine immediately in an emergency situation. The motor is stopped. The pressure
system is vented.
■ Pressure relief valve:
The pressure relief valve protects the system against excessive pressure. It is factory set.
■ Resistance thermometer:
Monitoring the airend discharge temperature protects the compressed air system from imper‐
missible temperature rises.
■ Door interlock switch:
The machine will stop automatically if a safety interlocked door or panel is opened or removed.
■ Housings and covers for moving parts and electrical connections.
Protect against accidental contact.
4.2.3 Floating relay contacts

Floating relay contacts are provided for the transfer of signals, messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

Keys
Fig. 6 Keys – overview

9_9463 22 E SK SFC 31

1 «OFF» Switches the machine off.
2 «ON» Switch on the machine.
3 «Cancel» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Accept» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.
7 «Left» Jumps to the left.
Moves the cursor position to the next left field.
8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.
13 «Time control» Switches the time control on and off.
Tab. 38 Keys
LEDs
Fig. 7 Indicators – overview

32 SK SFC 9_9463 22 E

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

18 Voltage applied to Continuous green light when voltage is applied to the controller.
controller
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Time control Continuous green light when the machine is in time control.
23 ON Continuous green light when the machine switched on.
Tab. 39 LEDs
RFID reader
RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided
with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 8 RFID reader

9_9463 22 E SK SFC 33

24 RFID RFID reader for the communication with a suitable RFID transponder.
Tab. 40 RFID reader
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.

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

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

■ The ON LED lights green.
■ The drive motor is stopped.
The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.

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

A small volume of air circulates through the bypass bore in the inlet valve, through the airend and
back to the inlet valve via the venting line.

34 SK SFC 9_9463 22 E
4.4.2 Control modes

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

■ DUAL
■ QUADRO
■ VARIO
Energy-efficient control modes for various applications:

Application Recommended
control mode
Compressed air station with one machine or several machines supplying VARIO
similar volumes.
Machine for peak load in a compressed air station DUAL
Machine for intermediate load in a compressed air station VARIO
Machine for basic load in a compressed air station QUADRO
Tab. 41 Energy-efficient control modes
The QUADRO control mode is preset by the factory, unless a different agreement has been made
with the manufacturer.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
QUADRO
In contrast to DUAL mode, the machine will switch in QUADRO after short periods between LOAD
to READY after being in IDLE.
Following extended times in the various operating modes, the machine switches from LOAD to
READY.
In this event, the controller considers the time in READY mode as standstill time. The time in LOAD
and IDLE operating modes are taken as minimum runtime.

9_9463 22 E SK SFC 35
4.5 Options
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
4.4.3 Variable speed drive with frequency converter (SFC)

If the machine runs in the LOAD mode, the ACTUAL value is compared with the TARGET value for
the network pressure. Depending on the pressure differential, the system controls the speed of the
drive motor and, thus, the airend.
The speed of the airend determines the delivered compressed air flow rate and the working pres‐
sure.
These changes in speed match the delivered compressed air flow rate to the air consumption and
keep the network pressure as constant and as close as possible to the system target pressure.
This functions within the control range of the machine between the minimum and maximum flow
rate (Qmin and Qmax).
If the compressed air demand falls below the minimum flow rate of the compressor (Qmin) the net‐
work pressure will continue to rise.
The machine switches to IDLE, at the latest when the pressure at the machine’s compressed air
outlet rises above the adjustable pressure rise value (pA). The pressure rise value above network
set-point pressure (pA) can be set from 0.2 to 2 bar.
Depending on the set pressure rise value, the machine will switch to IDLE or READY at
0.4 bar above maximum gauge working pressure at the latest.
This increase in pressure is to be taken into account in the design of the overall compressed
air supply system.
Further information Detailed information can be found in the SIGMA CONTROL 2 user manual.
4.5 Options
The options available for your machine are described below.
4.5.1 Option C3/C48

SIGMA CONTROL 2 controller: Connection to control technology
Connection to various control technology systems is possible with the C3 option.
Option C3 Option C48

Main Control System (MCS): Main Control System Input Output (MCSIO):
■ Slot for a communication mod‐ ■ Without slot for a communication module to connect to a
ule to connect to a control control technology system
technology system ■ Digital and analogue inputs and outputs integrated
Input-Output-Module (IOM):
■ Module with digital and ana‐
logue inputs and outputs
Tab. 42 Components

36 SK SFC 9_9463 22 E
4.5 Options
4.5.2 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 9 Machine mountings
4.5.3 Option W1
Prepared for external heat recovery
The cooling oil circuit includes 2 valves regulating the cooling oil temperature:
■ Thermostatic valve, machine
■ Thermostatic valve, heat recovery system
The thermostatic valves ensure that the cooling oil is kept at the ideal temperature for machine op‐
eration.
The thermostatic valve of the heat recovery system opens first so that surplus heat is released into
the heat recovery system. If the heat recovery system cannot carry away enough heat, the thermo‐
static valve of the machine opens to allow hot oil through the oil cooler circuit.
Condition:
Opening temperature machine thermostatic valve = Opening temperature heat recovery ther‐
mostatic valve
The heat available for recovery depends on the individual operating conditions of the machine.
Connections are provided for an external system to recover surplus heat.
The thermostatic valve of the heat recovery system does not function when the machine is deliv‐
ered. The necessary working element must be installed when installing the heat recovery system.
If necessary, the operating element in the machine's thermostatic valve can be exchanged for one
with a higher opening temperature. The opening temperature depends on operating and ambient
conditions.
Working elements are marked with their opening temperature [°C].
If the cooling oil temperature is too low, condensate can form and damage the machine.
➤ Consult KAESER Service on components and layout to ensure proper functioning of the
cooling and heat recovery systems.

9_9463 22 E SK SFC 37
5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated have a decisive effect on safety.

➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

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

5.2.1 Determining location and clearances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation of the machine room is provided below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult KAESER if they cannot be kept to.
Precondition The floor must be level, firm and capable of bearing the mass of the machine.

38 SK SFC 9_9463 22 E
Fig. 10 Recommended machine placement and dimensions [mm]

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

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

9_9463 22 E SK SFC 39
5.2.3 Exhaust duct design

The machine can only overcome the air resistance at the cooling air inlet and exhaust determined
by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐
ing.
➤ Consult the KAESER SERVICE representative before deciding on:
■ Design of the exhaust air ducting
■ Transition between the machine and the exhaust air duct
■ Length of the ducting
■ Number of duct bends
■ Design of flaps or shutters
Use only motorised ventilation flaps and louvers on variable frequency drive (SFC) machines.
Flaps or shutters that are opened by the the action of airflow against the force of gravity do
not open sufficiently at low compressor drive motor speeds.
Further information Further information on the design of exhaust air ducts can be found in chapter 13.2.

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

40 SK SFC 9_9463 22 E
6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Installation work may only be carried out by authorised personnel.
5 minutes.
pressure.
in serious injury.

9_9463 22 E SK SFC 41
6 Installation


1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Connecting the machine with the compressed air network

Condensate in the compressed air network can damage the pipework:
➤ Install only corrosion-resistant pipes.
➤ Use fluoroelastomers as sealing material for seals.
➤ Note the electro-chemical voltage sequence.
➤ Consult with KAESER for suitable materials for the compressed air network.
Precondition The compressed air system is vented completely to atmospheric pressure.
Fig. 11 Compressed air pipework

1 Flexible pressure hose
2 Shut-off valve
➤ Do not induce any forces into the machine for which the compressive forces must be bal‐
anced by bracing.
1. WARNING!
Serious injury or death can result from loosening or opening components under pressure.
2. A shut-off valve must be installed by the user in the connection line.
3. Connect a flexible pressure hose.
Further information The dimensional drawing in chapter 13.2 provides the size and position of the connection ports.

42 SK SFC 9_9463 22 E
6 Installation

Material Retrofit kit: "External pressure transducer SIGMA CONTROL 2"
Use suitable screened, copper-core cable (e.g.: LIYCY 2x0.75 mm2 for ambient temperatures up to
30 °C and wiring method C).
Cable length between the machine and the pressure transducer: <30 m
By means of a pressure transducer, the pressure in the compressed air network can be measured
at any selected location and this signal used to regulate the compressor.
This ensures optimum compressor regulation with regard to the network pressure at the selected
location.
Safety monitoring of the machine's internal pressure is unaffected.
Your authorized KAESER SERVICE technician will be glad to provide support on planning
and executing an individual solution.
1. Install the pressure transducer at the selected location in the compressed air network.
2. Using a suitable cable, connect the pressure transducer to a spare analog input.
➤ Connect as large an area of the screening as possible to the mounting plate in the control
cabinet or use an EMC fitting to make contact.
3. When commissioning the machine with SIGMA CONTROL 2, select the <Network actual
pressure> setting in the <AII> menu.
4. Select and activate the used analog input (AII).
Further information The electrical diagram in chapter 13.3 contains further details of the pressure transducer connec‐
tion.
6.5 Connecting the machine to the power supply

Precondition The power supply is switched off,
The voltage in the intermediate circuit capacitors of the frequency converter is reduced.
The tolerance limits of the mains voltage (power supply) are within the permissible tolerance limits
of the rated voltage (machine).
1. The power supply must only be connected by authorised installation personnel or an author‐
ised electrician.
2. Carry out safety measures as stipulated in relevant regulations (e.g. IEC 364 or
DIN VDE 0100) and in applicable national accident prevention regulations (BGV A3 in Germa‐
ny). In addition, observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐
nect in response to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.

9_9463 22 E SK SFC 43
6 Installation
6.6 Options
5. The user is required to fit the machine with a lockable isolating device which must comply with
the requirements of EN60204-1:2006, 5.3.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the control voltage transformer is connected according to the supply voltage.
7. If provided:
Check that the tappings on the control voltage transformer in the frequency converter cabinet
are connected according to the supply voltage.
8. DANGER!
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
voltage.
9. Connect the machine to the power supply.
10. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The wiring diagram in chapter 13.3 contains further details regarding the electrical power supply
connection.
6.6 Options
6.6.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.
6.6.2 Option W1
Connecting the external heat recovery system
An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit
within the compressor. Damage to the machine will follow.
➤ Consult KAESER on a suitable heat exchanger and have KAESER SERVICE do the installa‐
tion.
Further information The dimensional drawing in chapter 13.2 gives the flow direction, size and position of the connec‐
tion ports.

44 SK SFC 9_9463 22 E
7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.

➤ Commissioning tasks may only be carried out by authorised personnel!
5 minutes.
pressure.
in serious injury.

9_9463 22 E SK SFC 45
7 Initial Start-up


Incorrect or improper commissioning can cause injury to persons and damage to the machine.
➤ Commissioning may be carried out only by authorised installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage/standstill
Storage Measure
duration/standstill
period
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Manually fill the airend with cooling oil.
➤ Have the frequency converter intermediate circuit capacitor formed (re‐
freshed) by an authorised KAESER SERVICE technician.
36 months ➤ Have the overall technical condition checked by an authorised
KAESER SERVICE technician.
Tab. 43 Re-commissioning after storage/standstill
7.3 Checking installation and operating conditions

➤ Check and confirm all the items in the checklist before commissioning the machine.

chapter
➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.5
➤ Are the tolerance limits of the mains voltage (power supply) within 13.3
the permissible tolerance limits of the nominal voltage (machine)?
(see nameplate in the control cabinet)
➤ Are the power supply cable conductor cross-sections and fuse rat‐ 2.14
ings adequate?
➤ Have all electrical connections been checked for tightness? –
➤ Has the inspection been repeated after 50 operating hours following
the initial commissioning?

46 SK SFC 9_9463 22 E
7 Initial Start-up

chapter
➤ Has the connection to the air system been made with a shut-off valve 6.3
and a flexible hose?
➤ Has the drive belt tension been checked? 10.9
➤ Is there sufficient cooling oil in the separator tank? 10.13
➤ Is there sufficient cooling oil in the airend? 7.5
➤ Is the machine firmly anchored to the floor? 6.6.1
(Option H1)
➤ Are door interlock switches aligned and their function checked? 7.7
➤ Are all access doors closed and latched and removable panels in –
place and secured?
Tab. 44 Installation conditions checklist

The frequency converter parameters are preset. Adjustment of parameters to suit operating condi‐
tions on site is done by trained and authorised personnel.
Changes to the factory settings may influence the whole machine. The machine may break down
or be damaged.
➤ Allow only trained and authorised personnel to make parameter changes.
7.5 Pouring cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend. In
order to avoid that the cooling oil exceeds the permissible level, drain the required quantity from
the de-pressurised oil separator tank.
Chapter 10.16 provides detailed information on how to drain cooling oil from the oil separator tank.
Material 0.5 l cooling oil

9_9463 22 E SK SFC 47
7 Initial Start-up
Fig. 12 Charging hole

1 Screw plug
2 Airend
1. Unscrew and remove the screw plug.

2. Pour in the cooling oil and retighten the screw plug.
3. Turn the rotors manually by means of the belt pulley to distribute the oil.

All access doors are closed.
All removable panels in place and secured.
1. Open the shut-off valve to the air network.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Controller on LED is lit continuously.
3. If required:
Change the display language as described in chapter 7.9.
The compressor motor runs up and after a short time the machine switches to LOAD and deliv‐
ers compressed air.
➤ Watch for any faults occurring in the first hour of operation.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
7.7 Checking the door interlock switch

The interlock switch automatically stops the machine as soon as the secured front access panel is
opened.
Check the interlock switch function when commissioning or re-commissioning the machine.
The door interlock switch is an important safety device.
The machine may only be operated with a correctly functioning interlock switch.

48 SK SFC 9_9463 22 E
7 Initial Start-up
Fig. 13 Position of the door interlock switch

1 Door interlock switch
2 Access panel
1. Open the access panel 2 after the machine has been switched on.
the machine shuts down automatically. The controller displays an alarm message.
2. Close the panel and acknowledge the alarm.
➤ Have the interlock switch checked by an authorised KAESER SERVICE Technician.

The system pressure pA is factory set to the highest possible value.
Adjustment is necessary for individual operating conditions.
Do not set the set point pressure of the machine higher than the maximum working pressure
of the compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To reduce the cycling (toggling) frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.
➤ Set the set point pressure as described in the SIGMA CONTROL 2 operating manual.

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.

9_9463 22 E SK SFC 49
7 Initial Start-up
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
6.1 bar 80.0 ° C
–––––––– de_DE Deutsch –––––––– Current language (active line)
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.
Result The display texts are now in the selected language.

50 SK SFC 9_9463 22 E
8 Operation
8 Operation
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.
Fig. 14 Switching on and off

1 ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Voltage applied to controller LED
8.1.1 Switching on
All access doors and panels are closed and secure.
1. Switch on the power supply isolating device.

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

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

9_9463 22 E SK SFC 51
8 Operation
Result The Voltage applied to controller LED extinguishes. The machine is switched off and disconnected
from the mains supply.
In rare cases, you may want to shut down the machine immediately and cannot wait until the
automatic shut-down process is finished.
➤ Press «OFF» once again.

The EMERGENCY STOP control device is located below the control panel.
Fig. 15 Switching off in an emergency

Switching off
➤ Press the EMERGENCY STOP control device.
Result The EMERGENCY STOP control device remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
1. Turn the EMERGENCY STOP control device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Using the remote control for switching on and off

Precondition A link to the remote control centre exists.

52 SK SFC 9_9463 22 E
8 Operation
Fig. 16 Using the remote control for switching on and off

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

2. Label the starting device in the remote control centre as follows:

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 46 Remote control identification
3. Press the «remote control» key.

The remote control LED lights. The machine can be remotely controlled.

Precondition The timer is programmed.

9_9463 22 E SK SFC 53
8 Operation
Fig. 17 Using the timer for switching on and off

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

2. Press «Timer».
The time control LED lights. The timer switches the machine on and off.

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O.

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

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

54 SK SFC 9_9463 22 E
8 Operation
Fig. 18 Acknowledging messages

10 Warning LED (yellow)
11 Fault LED (red)
12 «Acknowledge» key
Alarm message
An alarm shuts the machine down automatically. The Fault LED flashes red.

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

maintenance has been carried out.

The Warning LED extinguishes.
Further information Please refer to the SIGMA CONTROL 2 operating manual for a list of possible warning messages
during operation.

9_9463 22 E SK SFC 55

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

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

56 SK SFC 9_9463 22 E
9.2 Other faults

Cooling oil leaking into the ma‐ Hose coupling or maintenance Remove coupling or mainte‐
chine interior. hose still plugged into the nance hose.
oil separator tank.
Oil cooler leaking. Call KAESER SERVICE.
Leaking pipe joints. Tighten pipe joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐
high. ing oil.
Oil separator cartridge split. Changing the oil separator car‐
tridge
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line clogged. Check the dirt trap strainer in
the oil return line.
Tab. 48 Other faults and remedies

9_9463 22 E SK SFC 57
10 Maintenance
10 Maintenance
Follow the instructions below to ensure safe machine maintenance.

➤ Allow maintenance work to be performed by authorised personnel only.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 49 Advise others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed.
voltage is present.
5 minutes.
pressure.

58 SK SFC 9_9463 22 E
10 Maintenance
➤ Vent all pressurized components and enclosures.
in serious injury.
voltage is present.


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

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.19.
10.2.2 Resetting maintenance interval counters

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

9_9463 22 E SK SFC 59
10 Maintenance
Precondition Maintenance performed and

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

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

Weekly Check the cooling oil level. 10.13
Cooler: 10.3
up to 1000 h Clean the cooler. 10.5
Check the air filter. 10.7
Cooler: 10.3
up to 3000 h Control cabinet: 10.4
Cooler: 10.3
Display: Maintain the drive belt. 10.9
SIGMA CONTROL 2 Change the air filter. 10.7
Display: Change the oil filter. 10.17
SIGMA CONTROL 2 Change the oil separator cartridge. 10.18
at least annually
Variable, see table 51 Change the cooling oil. 10.16
up to 12000 h Replace the drive belt. 10.9
h = operating hours

60 SK SFC 9_9463 22 E
10 Maintenance
Interval Maintenance task see chapter

Annually Check the pressure relief valve. 10.10
Check the function: 10.11
Safety shut-down due to excessive airend discharge tem‐
perature
Check the EMERGENCY STOP control device. 10.12
Check the function: 7.7
Safety shut-down when the machine is opened
Check the cooler for leaks. 10.5
Maintain the heat recovery system. 10.6
Check that all electrical connections are tight. –
h = operating hours
Tab. 50 Regular maintenance tasks
10.2.4 Cooling oil Change interval

Duty cycles and ambient conditions are important factors influencing the number and length of the
oil change intervals.
KAESER SERVICE will support you in determining appropriate intervals and provide informa‐
tion on the possibilities of oil analysis.
➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary; log the results in table 51 for fu‐
ture reference.
Maximum permissible oil change interval

[operating hours/years]
SIGMA FLUID Favourable operating Unfavourable operat‐ My operating condi‐
conditions* ing conditions tions
S-460 6000**/2 4000/1
S-570 6000**/2 4000/1
MOL 3000/1 2000/1
FG-460 3000/1 2000/1
FG-680 3000/1 2000/1
PANO‐ 3000/1 2000/1
LIN HLP SYNTH 46
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Change intervals of >6000 perating hours are not permissible without an oil analysis.
Tab. 51 Cooling oil Change intervals
10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Only an authorised KAESER SERVICE technician should carry out service work.

9_9463 22 E SK SFC 61
10 Maintenance
➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐
count.
Interval Service task

Display: Service valves.
SIGMA CONTROL 2 Compressor drive motor:
up to 36000 h Have the plastic pipes and hose lines been replaced.
est.
up to 36000 h Replace the control cabinet fan.
After 20 years at the lat‐ Replace safety-relevant components of the safety functions.
est
h = operating hours
Tab. 52 Regular service tasks

The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the
components is no longer ensured.
Material Filter mats:

Warm water and household detergent

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


62 SK SFC 9_9463 22 E
10 Maintenance
3. Change the filter mat if cleaning is not possible or if the change interval has expired.

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

Precondition The power supply isolator is switched off (all poles),

the device is secured to prevent switching back on,
Fig. 20 Switching cabinet ventilation

1 Ventilation grille
2 Filter mat
1. Carefully remove the ventilation grille and take out the filter mat.
3. Replace the filter mat if cleaning is not possible or if the change interval has expired.
4. Insert the filter mat in the frame and latch in the ventilation grille.

Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.

9_9463 22 E SK SFC 63
10 Maintenance
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the motors resulting in increased wear
and tear.
➤ Have the authorised KAESER SERVICE technician clean the cooling air ducts.
Material Brush and vacuum cleaner

Face mask (as required)


1 Filter mat
Cleaning the cooler and radiator
A filter mat helps to keep the cooler clean. Despite this fact, the cooler will clog over a period of
time.
Do not use sharp objects to clean the cooler. It could be damaged.
Avoid creating clouds of dust.
2. Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
➤ Have stubborn clogging removed by an authorized KAESER SERVICE technician.
Checking the cooler for leaks
➤ Carry out visual inspection: Did cooling oil escape?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by a KAESER SERVICE technician.

64 SK SFC 9_9463 22 E
10 Maintenance
10.6 Maintaining the external heat recovery system
10.6 Option W1
Maintaining the external heat recovery system
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is depend‐
ant on the characteristics of the heat transfer medium.
➤ Have the external heat recovery system checked annually by KAESER Service.
10.7 Air Filter Maintenance

Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress the pressure system and cause damage to the machine.
The air filter element cannot be cleaned.
Material Replacement part
Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.
Fig. 22 Air filter maintenance

1 Snap fastener
2 Air filter element
3 Air filter housing
1. Release the spring clips and remove the element.

2. Clean all parts and sealing surfaces.
3. Insert the new element in the housing.
4. Clip the air filter housing onto the inlet valve.

9_9463 22 E SK SFC 65
10 Maintenance
10.8 Compressor motor maintenance
10.8 Compressor motor maintenance

The anti-friction bearings of the compressor motor are permanently greased. Re-greasing is not
necessary.
➤ Have the anti-friction bearings checked by an authorised KAESER SERVICE technician in the
course of a maintenance visit.
10.9 Drive belt maintenance

Material Spare parts (if required)

WARNING
Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐
ties.
➤ Switch off and lock out the power supply isolating device and verify the absence of volt‐
age.
Fig. 23 Drive belt maintenance

1 Clamping nut
2 Clamping nut
3 Marker pin (shown as: belt tensioning required)
Checking the belt tension and adjustment
The tensioning device uses spring force to apply correct tension to the belt.
Adjust the tension when the marker pin reaches the top end of the elongated hole.
The marker pin can be seen through a viewing window from outside. This means that belt tension
can be checked without opening the machine.
1. Loosen the locking nut 2 .

66 SK SFC 9_9463 22 E
10 Maintenance
2. Use the adjusting nut 1 to adjust the spring tension until the marker pin reaches the lower end
of the elongated hole.
3. Tighten the locking nut 2 .
Visually check for damages.
1. Turn the pulley by hand so that all of the belt can be inspected for damage.
2. In case of damage: Replace the drive belt immediately.
Changing the belt
1. Loosen the locking nut 2 .

2. Turn adjusting nut 1 to loosen the tension on the belt until it can be removed from the pulley.
3. Install the new belt and use the adjusting nut 1 to adjust tension until the marker pin reaches
the lower end of the elongated hole.
4. Tighten the locking nut 2 .

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blow off protection and air system pressure monitoring are switched off during the test. In normal
operation, the blow-off protection will switch off the machine before the pressure relief valve re‐
sponds. During the inspection, the blow-off protection will switch off the machine only when the ac‐
tivating pressure of the pressure relief valve has been exceeded by 1 bar.
➤ Follow the detailed description of this procedure in theSIGMA CONTROL 2 operating
manual
➤ Never operate the machine without a correctly functioning pressure relief valve.
➤ Have a defect pressure relief valve replaced immediately.
WARNING
Excessive noise is caused when the pressure relief valve blows off!
➤ Wear hearing protection.
1. Close the user's shut-off valve between the machine and the air distribution network.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Log on to SIGMA CONTROL 2 with access level 2.
4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. WARNING!
Risk of burns due to released cooling oil and compressed air when blowing off the pressure
relief valve!
➤ Wear eye protection.

9_9463 22 E SK SFC 67
10 Maintenance
10.11 Check the safety shut-down due to excessive airend discharge temperature.
6. End the test as soon as the pressure relief valve blows off or working pressure exceeds the
activating pressure of the pressure relief valve by nearly 1 bar.
7. If necessary, vent the machine and replace the defective pressure relief valve.
8. Deactivate the test function
10.11 Check the safety shut-down due to excessive airend discharge

temperature.
The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐
nician.
10.12 Check the EMERGENCY STOP control device
Fig. 24 Check the EMERGENCY STOP control device

Precondition Compressor motor running
1. Press the EMERGENCY STOP control device.

The compressor motor stops, the pressure system is vented, and the machine is prevented
from automatically re-starting.
The compressor motor does not stop?
The safety function of the EMERGENCY STOP device is no longer ensured.
➤ Shut down the machine immediately and call KAESER SERVICE.
2. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
3. Acknowledge the alarm message.

The sight glass allows a risk-free reading of the cooling oil level. The oil indicator should be fully
filled with oil when the machine is at standstill. The correct oil level cannot be seen.

68 SK SFC 9_9463 22 E
10 Maintenance
The ideal situation is with the oil level around the optimum mark when the machine is running.
Operating state Minimum oil level Maximum oil level
LOAD
Tab. 53 Permissible cooling oil level under LOAD
In frequency-controlled compressors (SFC) the oil level indicator sis only accurate when the
machine is running at or near maximum speed.
The lower the pressure at the compressed air outlet, the higher the speed.
Precondition The machine has been running at least 5 minutes under LOAD.
Fig. 25 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum oil level
➤ Check the oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.

separator tank.

9_9463 22 E SK SFC 69
10 Maintenance
CAUTION
Fig. 26 Venting the machine

1 Hose coupling (air cooler venting) 7 Shut-off valve

ted.

70 SK SFC 9_9463 22 E
10 Maintenance
sure/check valve.

separator tank.
Fig. 27 Replenish cooling oil

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

2. Fill with cooling oil and test run as described in section 10.15.2.

9_9463 22 E SK SFC 71
10 Maintenance
10.15.1 Venting the machine (de-pressurising)

CAUTION

ted.
sure/check valve.
10.15.2 Topping up with cooling oil and trial run

Replenish cooling oil
A sticker on the oil separator tank specifies the type of oil used.

72 SK SFC 9_9463 22 E
10 Maintenance
1. WARNING!
Compressed air!
2. NOTICE!
The machine could be damaged by unsuitable oil!
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
4. Top up to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.

Drain the oil completely from the following components:
■ Oil separator tank
■ Oil cooler
■ Thermostatic valve (Option W1)
Always change the oil filter and oil separator cartridge when changing the oil.
Compressed air helps to expel the oil. This compressed air can be taken either from the compres‐
sor itself or from an external source.
An external source of compressed air is necessary in the following cases (examples):

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.
Material Cooling oil

The maintenance hose with hose coupling and shut-off valve is stowed beneath the oil separator
tank.
CAUTION

9_9463 22 E SK SFC 73
10 Maintenance
Fig. 28 Changing the cooling oil, oil separator tank

1 Hose coupling (air cooler venting) A Shut-off valve open
2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
4 Oil filler port with plug 9 Hose coupling (oil drainage)
5 Cooling oil level indicator. 10 Shut-off valve (venting line)
6 Plug-in nozzle 11 Shut-off valve (oil drainage)
7 Shut-off valve
Changing the oil with internal pressure Oil change with an external compressed air
source
The machine has been running at least 5 mi‐ Cut-off the electrical power supply via the power
nutes in LOAD mode. supply isolating device,
The machine is fully vented, ensure that the device is locked off,
the pressure gauge on the oil separator tank verify the absence of any voltage.
reads 0 bar. The machine is fully vented,
1. Close the shut-off valve 10 in the venting the pressure gauge on the oil separator tank
line. reads 0 bar.
2. Start the machine and watch the oil separa‐ An external source of compressed air is availa‐
tor tank pressure gauge 2 until it reads 3– ble.
5 bar. 1. Close the shut-off valve 10 in the venting
3. Switch off the machine. line.
4. Wait at least 2 minutes to allow the oil to 2. With the shut-off valve closed, insert the
flow back to the separator tank. plug-in nozzle 6 into the hose coupling 3 .
3. Connect the maintenance hose to the exter‐
nal air supply.
4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3–
5 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.

74 SK SFC 9_9463 22 E
10 Maintenance
Draining the oil from the separator tank
Contact KAESER SERVICE if condensate is detected in the cooling oil.

It is necessary to adapt the airend discharge temperature to individual ambient conditions.

5. Slowly open the shut-off valve 7 in the maintenance hose and allow the cooling oil to drain
completely.
Draining the oil from the cooler
Fig. 29 Changing the cooling oil Oil cooler

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

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

9_9463 22 E SK SFC 75
10 Maintenance
Option W1 Draining the oil from the thermostatic valve
A drain plug is provided to drain oil from the thermostatic valve. If the machine is connected to an
external heat recovery system, oil should also be drained from the heat exchanger at a suitable
point.
Precondition The external heat recover system is de-pressurised.
Fig. 30 Changing the cooling oil, heat recovery system

2 Thermostatic valve
3 Screw plug

2. Remove the drain plug 3 and allow the oil to drain completely.
3. Replace the plug 3 .
Filling with cooling oil
1. WARNING!
Compressed air!
2. Slowly unscrew the filler plug 4 (see illustration 28).
3. Fill with cooling oil.
4. Check the filler plug and ring seal for damage and screw the plug back in again.
3. Switch on the electrical power supply via the power supply isolating device and reset the main‐
tenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.

76 SK SFC 9_9463 22 E
10 Maintenance

Material Spares

CAUTION
Fig. 31 Changing the oil filter

1 Oil filter
2 Direction to unscrew
Changing the oil filter
1. WARNING!
Compressed air!
2. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐
ronmental protection regulations.
3. Lightly oil the new filter's gasket.
4. Turn the oil filter clockwise by hand to tighten.

9_9463 22 E SK SFC 77
10 Maintenance
Starting the machine and carrying out a trial run
5. Switch off the machine and check visually for leaks.

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

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

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.

78 SK SFC 9_9463 22 E
10 Maintenance
Fig. 32 Changing the oil separator cartridge

14 Cover 20 Screw connection
15 Dirt trap 21 seal
16 Air pipe 23 Oil separator cartridge
17 Retaining screw 30 Ball (functioning as a check valve)
19 Self-locking nut 31 Strainer
Changing the oil separator cartridge
1. WARNING!
Compressed air!
Compressed air and pressurised devices can cause serious injury or death if the contained
2. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
3. Unscrew the nut 19 and turn the air pipe 16 to one side.
4. Remove the cover fixing screws 17 and carefully remove the cover 14 .
5. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac‐
cording to environmental protection regulations.
6. Clean all sealing faces.
7. Insert the new oil separator cartridge with gaskets and re-fix the cover.
8. Renew the O-ring and strainer in the dirt trap 15 .
➤ Make sure the ball 30 is properly seated.
The ball prevents cooling oil being pressed into the separator cartridge.
9. Attach the air pipe to the cover 14 with a new, self-locking nut.
10. Replace and tighten all fittings.

9_9463 22 E SK SFC 79
10 Maintenance
Start the machine and carry out a trial run
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.

80 SK SFC 9_9463 22 E
10 Maintenance

Machine number:
➤ Enter maintenance and service work carried out in the list.
Date Maintenance task carried out Operating hours Signature
Tab. 54 Logged maintenance tasks

9_9463 22 E SK SFC 81

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

KAESER consumable parts and operating materials are original KAESER products. They are spe‐
cifically selected for use in KAESER machines.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from damage.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spares or operating fluids/materials.
➤ Use only original parts and operating fluids/materials.
➤ Have an authorized KAESER SERVICE technician carry out regular maintenance.
Machine
Name Number
Air filter element 1250
Filter mat (cooler) 1050
Filter mat (control cabinet) 1100
Oil filter 1200
Oil separator cartridge 1450
Cooling oil 1600
Drive belt 1801
Condensate drain: —
Service-Unit
Tab. 55 Consumable parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,
■ The security of genuine KAESER spares.
■ Increased legal certainty as all regulations are kept to.

82 SK SFC 9_9463 22 E
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.

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

9_9463 22 E SK SFC 83

84 SK SFC 9_9463 22 E

9_9463 22 E SK SFC 85

De-commissioning is necessary, for example, under the following circumstances:
■ The machine is (temporarily) not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.
➤ The following tasks are to be performed by authorised personnel only.
12.1.1 Temporary de-commissioning

Precondition The machine can be started at regular intervals.
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.
12.1.2 Long-term de-commissioning

Precondition Immediately prior to de-commissioning, run the machine in LOAD operation for at least 30 minutes.
12.1.2.1 Draining condensate
If the machine is equipped with a condensate drain, drain condensate from the condensate drain.
1. Drain condensate from the condensate drain and dispose of according to applicable environ‐
mental protection regulations.
2. Remove the user-supplied condensate lines.
The condensate drains are not supplied with power when the machine is switched off?
➤ Detach and drain the condensate drains.
12.1.2.2 Isolating the machine from supply lines

it has been locked off against unintentional reactivation and
The machine is fully vented (depressurised).
The user's shut-off valve to the compressed air network is closed or the compressed air network
has been fully vented.
1. Allow the machine to completely cool down.

2. Detach the power supply and connecting line to the compressed air network at the user side.
3. Option W1:
Remove the user-supplied connecting lines.
4. Properly close all open connecting ports.

86 SK SFC 9_9463 22 E
12.2 Packing
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact
KAESER SERVICE for more information.
Material Desiccant
Plastic sheeting
Wooden crate

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

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
The following measures also apply to machines not yet commissioned.
Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. NOTICE!
Moisture and frost can damage the machine!
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Mass and centre of gravity determine the most suitable method of transportation. The centre of
gravity is shown in the drawing in chapter 13.2.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only by forklift truck or lifting gear and only by personnel trained in the safe transportation
of loads.
➤ Ensure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The whole machine is over the forks.

9_9463 22 E SK SFC 87
12.4 Transport
Fig. 33 Transporting with a forklift truck
1. Take note of the centre of gravity.

2. Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transport with a hoist

Only suitable and approved load-carrying and attachment devices ensure proper transport of the
machine with a hoist (e.g., crane). Suitable crossbeams ensure sufficient distance of the attach‐
ment resources from the machine housing to prevent damage.
The machine is not equipped with fastening points.
Examples of unsuitable fastening points:

■ Pipe sockets
■ Flanges
■ Attached components such as centrifugal separators, condensate drains or filters
■ Rain protection covers
➤ Consult KAESER if you require suitable load-carrying and attachment devices or have
questions regarding the correct use.
Precondition Load-carrying and attachment devices meet the local safety regulations.
The hoist, load-carrying and attachment devices or the lifted machine do not endanger personnel.

88 SK SFC 9_9463 22 E
12.4 Transport
Fig. 34 Transporting with a crane

1 Load carrying devices
2 Attachment resources
3 Crossbeam
1. WARNING!
Risk of accident caused by incorrect use of load-carrying and attachment devices!
➤ Comply with permissible load limits.
➤ Comply with specific safety information of used load-carrying and attachment devices.
2. Properly use load-carrying and attachment devices:
■ Ensure proper distribution of the fastening points relative to the centre of gravity position
(symmetrical load distribution).
■ Ensure equal slope angles of 15° to 45° for attachment devices with multiple strands.
─ Slope angles between 45° and 60° may be unsuitable.
─ Slope angles larger than 60° are prohibited.
■ Ensure the maximum incline of 6° of the machine to the horizontal.
■ Ensure sufficient distance of the attachment devices to the machine.
■ Ensure a positive stability height: Dimension B > Dimension A
■ Do not attach the attachment devices to any machine component.
3. Carry out a lifting test:
Slightly lift the machine to check whether machine remains in horizontal position and does not
teeter.
4. Transport the machine only after a successful lifting test.

9_9463 22 E SK SFC 89
12.5 Disposal
12.5 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
1. Completely drain the cooling oil from the machine.

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

➤ Refrigerant and oil must be drained and disposed of by an authorized specialist workshop.
12.5.1 Battery disposal in accordance with local environmental regulations.

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be delivered to the
national battery collection system. This procedure facilitates the handling and recycling of batteries.
In EU Member States, as per Directive 2006/66 / EC, used batteries must be returned to the point
of sale or to a disposal system (free of charge). These disposal facilities may be local recycling
yards for used electric and electronic devices and their points of sale.
The SIGMA CONTROL 2controller’s enclosure houses a battery.
Fig. 35 Battery labelling

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

friendly manner.
You actively contribute to the protection of our environment when you bring used batteries to
the appropriate recycling system.
Further information Refer to the SIGMA CONTROL 2user manual for details regarding battery removal and replace‐
ment.

90 SK SFC 9_9463 22 E
13 Annex
13 Annex

9_9463 22 E SK SFC 91
13 Annex

92 SK SFC 9_9463 22 E
13 Annex

9_9463 22 E SK SFC 93
13 Annex

94 SK SFC 9_9463 22 E
13 Annex

9_9463 22 E SK SFC 95
13 Annex

96 SK SFC 9_9463 22 E
13 Annex

9_9463 22 E SK SFC 97
98
Outlet: compressed air 430 89 Outlet: cooling air 895
Inlet:
cooling air
500
47
13
13.2
SK SFC
1260
Inlet:
W1 ID G 3/4

cooling air
48
ID G 1
Operating Manual
637
605
Annex
540
196
29 O 100 65 685
177
100
140
628 60 630 815
Dimensional drawing
750
768 25

22
152
529 H1 H1
Z
50
50 65 90° O 13 65 685
100
140
O 140
420
60 630
O
26
41
O
x 460
3
Electrical connection
ID : Internal thread
Change number Projection Scale Date Name
1:15 Drawn 14.05.2014 ROEBLITZ1
Document TZM Original Edited 28.05.2014 ROEBLITZ1 Language Sheet
: Center of gravity
Position marginally dependent on design Document TZD Designation
W1 prepared for ext. heat recov. 10274027 D 00
SK.2 SFC K1
H1 Machine mountings Status Dimension and connection dim.
Transport opening ≥ machine width + 100mm Released

Stand 13.02.2013
K1 Air cooling
9_9463 22 E
99 SK SFC 9_9463 22 E
Rotary screw compressor Operating Manual
Die Zeichnung bleibt unser ausschließliches Eigentum. Sie wird nur zu dem vereinbarten Zweck anvertraut und darf zu keinem anderen Zweck verwendet werden. Drawings remain our exclusive property. They are entrusted only for the agreed purpose. Copies or any other reproduction, including storage, treatment and Entwicklungsbedingte Änderungen
Kopien oder sonstige Vervielfältigungen einschließlich Speicherung, Verarbeitung oder Verbreitung unter Verwendung elektronischer Systeme dürfen nur zu dem dissemination by use of electronic systems must not be made for any other than the agreed purpose. Neither originals nor reproductions may be given to or made vorbehalten. Zeichnung darf nur über CAD
vereinbarten Zweck angefertigt werden. Weder Original noch Vervielfältigungen dürfen Dritten ausgehändigt oder in sonstiger Weise zugänglich gemacht werden. available to third parties. geändert werden.
.
.
SK 25 : V = 3.000 m³/h ∆p max. 30 Pa
SK 22 : V = 2.500 m³/h ∆p max. 30 Pa
637 500
17
297
782
430
Cooling air outlet
22
152
Index
Dokument-Nr.
Techn. Dienst Nr.
T11330.00
Änderungs-Nr.
10183467 D 00
A3
Original
Maßstab
Bezeichnung
Gez.
.
Bearb.
Cooling air inlet
Freigeg.
SK 22/25 K1
Datum
23.09.10
Name
Roeblitz1
23.09.10 Schubart, P.
E
SK 25 : V = 2.500 m³/h ∆p max. 30 Pa
SK 22 : V. = 2.000 m³/h ∆p max. 30 Pa
Sprache
loss for installed ducting

Total permissible pressure
Blatt
Dimensional drawing 13.2
Annex 13
13 Annex

100 SK SFC 9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
Electrical diagrams
Compressor series SK SFC
13
13.3
SK SFC
380V±10% 60Hz 440V±10% 60Hz
400V±10% 50Hz 460V±10% 60Hz
Operating Manual
Annex
TT/TN three-phase power supply with neutral point grounding

Electrical Diagram
ATTENTION !!! 400V±10% 50Hz

The document gives collective information on
power supply voltages and frequencies for all machines.
The voltage and frequency and local conditions under IT three-phase power supply with isolated neutral point
which any particular machine may be used

are given on the nameplate of the machine (option C35)
and in the accompanying service manual.
Manufacturer: KAESER KOMPRESSOREN SE

96450 Coburg
GERMANY
The drawings remain our exclusive property. They are entrusted

only for the agreed purpose. Copies or any other reproductions,
including storage, treatment and dissemination by use of
electronic systems must not be made for any other than the
agreed purpose. Neither originals nor reproductions must be
forwarded or otherwise made accessible to third parties.
c Datum 19.11.2018 E Cover page =

b Bearbeiter Taubmann/Seubert +
a Geprüft Geiger
Compressor SK SFC page 1
A Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS DSK.F-03107.02 1 Bl.
101
102
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
1 Cover page DSK.F-03107.02 1
2 List of contents ZSK.F-03107.02 1
3 general instructions USK.F-03107.02 1
4 electrical equipment identification USK.F-03107.02 2
5 Equipment parts list USK.F-03107.02 3
8 Circuit diagram Power switching SSK.F-03107.02 1
13
13.3
9 Circuit diagram Control voltage tapping SSK.F-03107.02 2
SK SFC
10 Circuit diagram Power supply unit SSK.F-03107.02 3
11 Circuit diagram IO-module/Configuration SSK.F-03107.02 4
12 Circuit diagram sensors/actuators SSK.F-03107.02 5
13 Circuit diagram Binary inputs / outputs FC SSK.F-03107.02 6
Operating Manual
14 Circuit diagram Volt-free contacts SSK.F-03107.02 7
Annex
15 Circuit diagram inputs/outputs SSK.F-03107.02 8

16 Circuit diagram transformer diagrams SSK.F-03107.02 9
17 Circuit diagram Handling: Terminals / Feed line connection SSK.F-03107.02 10
18 Terminal schedule screen rail FC, Volt-free contacts -X0 KSK.F-03107.02 1
19 Terminal schedule Terminal strip -X2,-X11 KSK.F-03107.02 2
Electrical Diagram
20 Component layout Mounting plate ASK.F-03107.02 1

c Datum 19.11.2018 List of contents =
a Geprüft Geiger
B Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS ZSK.F-03107.02 1 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
general instructions control cabinet wiring for non-designated conductors
with multi-standard stranded conductors
ATTENTION !!!
primary circuits: black
Install supplies, grounding and shock protection
to local safety regulations. Control voltage AC ungrounded: red 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Control voltage AC grounded: white 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Do not make or break
13
13.3
live plug-in connectors. Control voltage DC ungrounded: blue 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
SK SFC
Control voltage DC grounded: white/blue 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
external voltage: orange 1,5mm² H07V-K, 16AWG UL-Style 1015, CSA-TEW
measuring circuits: violet 1mm² H05V-K, 18AWG UL-Style 1015, CSA-TEW
Operating Manual
Annex
earth conductor: green/yellow H07V-K, UL-Style 1015, CSA-TEW
The cable types given in the plan are recommendations and

Electrical Diagram
technically equivalent alternatives are also possible.

c Datum 19.11.2018 general instructions =
a Geprüft Geiger
SC2 MCS USK.F-03107.02 5 Bl.
103
104
1 2 3 4 5 6 7 8
electrical equipment identification

general components Control sensors/actuators
-F11 Overload protection switch, -K20 Main Control System SC2 MCS -B1 Pressure transducer,
Control transformer -X1 Ethernet Air main pressure
-X2 IO-Bus -B2 Direction of rotation pressure switch
-K53 Coupling relay, Volt-free contacts
-K55 Coupling relay, Control cabinet ventilator -X3 RS485-FC (USS) -B40 Temperature probe,
-X4 Communication module (Bus) Airend discharge temperature
-M1 Compressor motor -X5 SD card slot -K1 Control valve
13
13.3
-M7.1,-M7.2 Control cabinet ventilator -X6 Earth connection
SK SFC
-R1 Mains choke
-R3 Tape-wound core -K21 IO-module SC2 IOM-1
-R11 Power supply filter internal
-X1 IO-Bus, Input
Operating Manual
Annex
-S1 EMERGENCY STOP pushbutton -X2 IO-Bus, Output

-S5 Door safety interlock switch -X3,-X8 digital inputs
-X4 Power supply unit,
-T1 Frequency converter
digital outputs
-T11 Control transformer
-X5,-X9 Relay outputs
-T21 Power unit
Electrical Diagram
-X6 Analog input, 4-20mA

-X7 Analog input, Pt100
external
-X11...-X13 analog inputs, 4-20mA
-X14...-X17 analog inputs, Pt100

-X18...-X29 digital inputs
-X30...-X32 digital outputs
terminal strips
-X0 Terminal strip, Power supply
-X2,-X11 Terminal strip, Control
c Datum 19.11.2018 electrical equipment identification

a Geprüft Geiger
SC2 MCS USK.F-03107.02 5 Bl.
9_9463 22 E
13 Annex
3
Bl.5
page
model SK 22 SFC
460 V ±10 %, 60 Hz
USK.F-03107.02
=
+
Motor -M1 11 kW 11 kW 11 kW
Control cabinet
Terminal strip -X0: U1/V1/W1/GRD 7.6836.00800 7.6836.00800 7.6836.00800
3x WKFN 16 D1/2/35 3x WKFN 16 D1/2/35 3x WKFN 16 D1/2/35
3x WKFN16 D1/2/SL/35 3x WKFN16 D1/2/SL/35 3x WKFN16 D1/2/SL/35
SC2 MCS
6SL3210-1PE22-7UL0 6SL3210-1PE22-7UL0 6SL3210-1PE22-7UL0
11 kW, 380 V-480 V 11 kW, 380 V-480 V 11 kW, 380 V-480 V
Control Unit 7.7830.00710 7.7830.00710 7.7830.00710
Mains choke -R1 7.7831.00320 7.7831.00320 7.7831.00320
Siemens 6SL3203-0CE23-8AA0 6SL3203-0CE23-8AA0 6SL3203-0CE23-8AA0
Power supply filter -R11 7.8832.00030 7.8832.00030 7.8832.00030
Siemens FS33891-50-07 FS33891-50-07 FS33891-50-07
Transformer -T11 7.2239.2 7.2239.2 7.2239.20070
B 0001091 B 0001091 USTE400
Compressor SK SFC
400 VA 400 VA 400 VA
Block diagram 1, Sht. 9 diagram 1, Sht. 9 diagram 2, Sht. 9

cables
motor cable -W211 Oilflex Control TM CY Oilflex Control TM CY Oilflex Control TM CY
4G10 mm² 4G10 mm² 4G10 mm²
Tape-wound core -R3 7.8538.0 7.8538.0 7.8538.0
power wiring -W280, -W281 H07V-K H07V-K H07V-K
3x1x10 mm² 3x1x10 mm² 3x1x10 mm²
black black black
Ursprung:
Ersatz für:
Ersatz durch:
Taubmann/Seubert
19.11.2018
Geiger
Bearbeiter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

9_9463 22 E SK SFC 105
13 Annex
4
Bl.5
page
model SK 25 SFC
460 V ±10 %, 60 Hz
USK.F-03107.02
=
+
Motor -M1 15 kW 15 kW 15 kW
Control cabinet
Terminal strip -X0: U1/V1/W1/GRD 7.6836.00800 7.6836.00800 7.6836.00800
3x WKFN 16 D1/2/35 3x WKFN 16 D1/2/35 3x WKFN 16 D1/2/35
3x WKFN16 D1/2/SL/35 3x WKFN16 D1/2/SL/35 3x WKFN16 D1/2/SL/35
SC2 MCS
6SL3210-1PE23-3UL0 6SL3210-1PE23-3UL0 6SL3210-1PE23-3UL0
15 kW, 380 V-480 V 15 kW, 380 V-480 V 15 kW, 380 V-480 V
Control Unit 7.7830.00710 7.7830.00710 7.7830.00710
Mains choke -R1 7.7831.00320 7.7831.00320 7.7831.00320
Siemens 6SL3203-0CE23-8AA0 6SL3203-0CE23-8AA0 6SL3203-0CE23-8AA0
Power supply filter -R11 7.8832.00030 7.8832.00030 7.8832.00030
Siemens FS33891-50-07 FS33891-50-07 FS33891-50-07
Transformer -T11 7.2239.2 7.2239.2 7.2239.20070
B 0001091 B 0001091 USTE400
Compressor SK SFC
400 VA 400 VA 400 VA
Block diagram 1, Sht. 9 diagram 1, Sht. 9 diagram 2, Sht. 9

cables
motor cable -W211 Oilflex Control TM CY Oilflex Control TM CY Oilflex Control TM CY
4G10 mm² 4G10 mm² 4G10 mm²
Tape-wound core -R3 7.8538.0 7.8538.0 7.8538.0
power wiring -W280, -W281 H07V-K H07V-K H07V-K
3x1x10 mm² 3x1x10 mm² 3x1x10 mm²
black black black
Ursprung:
Ersatz für:
Ersatz durch:
Taubmann/Seubert
19.11.2018
Geiger
Bearbeiter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

106 SK SFC 9_9463 22 E
13 Annex
5
Common parts
Bl.5
page
model SK 22/25 SFC
machine power supply 380 V±10 %, 60 Hz
400 V±10 %, 50 Hz
USK.F-03107.02
440 V±10 %, 60 Hz
=
+
460 V±10 %, 60 Hz
Terminal strip -X2, -X11 7.6836.00710, Wieland

Handling fig. 1, Sht. 10
Power supply -T21 7.7605P0
Prodrive PSDC24/2.5
Coupling relay -K53, -K55 7.3149.00660
Wieland FLARE-24V-1W-250V6A
Overload protection switch -F11 7.8742.01110
3RV2021-1AA10
SC2 MCS
1,1-1,6 A
Siemens setting: 1,1 A
Compressor control -K20 7.7601.0
Prodrive SIGMA CONTROL 2 MCS
IO-module -K21 7.7602.1
Prodrive SIGMA CONTROL 2 IOM
EMERGENCY STOP pushbutton -S1 7.3217.0
QRUV
bracket + Switching element 7.3218.0
MHTOO
Switching element 7.3119.0
Compressor SK SFC
Schlegel MTO
Control cabinet ventilator -M7.1, M7.2 7.2751.00411

LV300 / VDR / yellow
Outlet filter 7.2752.00010
Rübsamen&Herr GV300 / grey
Mounting plate KAESER 212661.00010
Ursprung:
Ersatz für:
Ersatz durch:
Taubmann/Seubert
19.11.2018
Geiger
Bearbeiter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

9_9463 22 E SK SFC 107
108
1 2 3 4 5 6 7 8
-X0 U1 L1
/2.1
**** V1 L2
/2.1
W1
PE
Feed line connection activation Control cabinet ventilator 2,5mm² black
see page 10 NSGAFöu
-K21 DOR 1.01 short circuit proof
10mm² green/yellow /4.3 COM
-W280 500V 70°C
6
X5
PE2
**** Int.
13
-X0 PE3
13.3
10mm² green/yellow
1L1
1L2
1L3
PE
SK SFC
500V 70°C
A1
-R1 -K55
Mounting plate ****
A2
2L1
2L2
2L3
-W281 -X0 PE3
PE2
Operating Manual
3L-
Annex
**** /6.3
L1
L2
L3
PE
10mm² green/yellow
-R11 14 11
500V 70°C
**** 6 12
Unit frame
L1'
L2'
L3'
PE
Electrical Diagram
-X11 5 L011
4mm² green/yellow /2.4
L1/U1
L2/V1
L3/W1
PE
DCP
R2
DCN
500V 70°C
12
14
+ - - -K55
PE1
-X11 PE2 -T1
6
**** AC 11
-X0
DC

SINAMICS
6
/6.2 T1.0 -X11 -X11 7

G120
DC
AC
L1
L1
Main switch, -M7.1 -M7.2

PE PE
PE
Fuse supplied 10mm² green/yellow
M M
V(2)
U(2)
W(2)
by user 500V 70°C -R3 20W 1~ 20W 1~
-T1
N
N
**** 230V 230V

50/60Hz 50/60Hz
PE1
PE2
-X11 -X11
-W211
****
-X11 05 -X11 04 L02
/2.1
Unit frame Oil separator
U
V
W
PE
L1 L2 L3 PE
M
See operating manual for supply 3~
cable cross-section and fusing
-M1 see: Equipment parts list
****
Function: Compressor motor activation Control cabinet ventilator
Group of functions: Main power supply Power switching
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Power switching SC2 MCS SSK.F-03107.02 10 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
L1 -X11 2 -X11 1 -X11 3 L01
/1.8 /3.1
L2
/1.8
3L+
/6.3
1
-W72
2
4
6
11
22
-F11 -S5 -S5
Door safety interlock switch
21
12
****
2
13
I>> I>> I>> -W72

13.3
1
3
5
26
SK SFC
-X2
1,5mm² black -W102
500V 70°C
11
31
21
-S1 -S1 -S1
Operating Manual
-T11
Annex
EMERGENCY STOP
32
22
12
2,5mm²
green/yellow
****
500V 70°C Int. Ext.
PE2
9
8
1
2
3
-X11 X3 X29
4
27
-X11 -X2
Electrical Diagram
L011 -K21 DI_PA DI -K21 DI_PA DI

model-specific /1.8
electrical diagram 1+2 DI 1.00 DI 1.07
/4.3 /4.3
see page 9
-X11 04 EMERGENCY STOP Door safety interlock switch
1,5mm²

green/yellow
-K21 DOR COM
500V 70°C COM
PE1
-X11 connection /4.3
9
8
s.b.c. X5
Int.
10VA
PE3
-X11
L02 -X11 01 -X11 01 L02

/1.8 /3.1

Function: 230V/1~/50/60Hz Door safety interlock switch / EMERGENCY STOP

Group of functions: Control voltage tapping Consumer external Safety chain
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Control voltage tapping SC2 MCS SSK.F-03107.02 10 Bl.
109
110
1 2 3 4 5 6 7 8
L01 -K20
/2.8
MCS
4mm² green/yellow 2,5mm² green/yellow X5
500V 70°C 500V 70°C SD card
-X11 PE1 X6
13
13.3
option COM-Module RS485-FC Ethernet IO-Bus
SK SFC
Control cabinet X4 X3 X1 X2
9 8 7 6 5 4 3 2 1
N P
/6.7 -W81
Operating Manual
BN
Annex
3x2x0,22mm²
WH /6.7
screened
-T21
1)
-K21 X1
Electrical Diagram
100- + -X2 3 2L+ I/O-BUS

/6.1 /4.3 X4
240V~ +
-X11 3 L1 3 L+
-
24V= 2 L-
IOM 1
-X11 03 N - -X2 03 2L-
/6.1 1 FE
2,5A -
short circuit proof I/O-BUS

500V 70°C
1,5mm² green/yellow X2
PE1
-X11
500V 70°C
PE2
-X11
L02
/2.8
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of functions: Control voltage
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Power supply unit SC2 MCS SSK.F-03107.02 10 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
-K21 IOM1 internal
11 1
DI_PA AII_PA
10 2
DI_PA AII 1.02
X6
9 3
/2.6 DI_PA AII_GND
8
/2.6 DI 1.00
7
13
1
13.3
DI 1.01 AIR 1.03

6
X7
2
SK SFC
X3
DI 1.02 AIR 1.03 -K21
5
DI 1.03
4 IOM1 external
DI 1.04 1
3 DI_PB
DI 1.05
Operating Manual
2
2 DI_PB /5.2 AII 1.00 X11 X22 DI 1.00
Annex
DI 1.06 3
1 DI_PB AII 1.01 X12 X23 DI 1.01
DI 1.07 4
DI_PB AII 1.02 X13 X24 DI 1.02
8 5
DOT 1.01 DI_PB /5.3 AIR 1.00 X14 X25 DI 1.03
7 6
Electrical Diagram
M24 DI_PB AIR 1.01 X15 X26 DI 1.04
X8
6 7
DOT 1.02 DI 1.08 AIR 1.02 X16 X27 DI 1.05
5 8
M24 DI 1.09 AIR 1.03 X17 X28 DI 1.06
X4
4 9
FE DI 1.10 DI 1.08 X18 X29 DI 1.07 /2.8
3 24V 10
/3.7 L+ DI 1.11 DI 1.09 X19 X30 DOT 1.00 /5.6
2 11

/3.7 0V L- DI 1.12 DI 1.14 X20 X31 DOT 1.01
1 12
/3.7 FE DI 1.13 /5.5 DI 1.15 X21 X32 DOT 1.02
9 1
/2.6 DOR COM DOR 1.05
8 2
DOR COM DOR COM
7 3
/6.6 DOR 1.00
6 4
/1.6 DOR 1.01 DOR 1.06
5 5
/6.7
X9
DOR 1.02 DOR COM
X5
4 6
DOR 1.03
3 7
DOR 1.07
2 8
DOR COM DOR COM
1 9
DOR 1.04
Function:
Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: IO-module/Configuration SC2 MCS SSK.F-03107.02 10 Bl.
111
112
1 2 3 4 5 6 7 8
-B1 -B40
1
P -B2
4...20mA P
2
Pt100
- + >1,0 bar
2
1
1
4
13
13.3
-W115 -W117 -W104
SK SFC
Operating Manual
Annex
Ext. Ext. Ext.
1
2
3
1
2
3
1
2
3
X11 X14 X21
-K21 AII AII_PA GND -K21 AIR_A Shield AIR_B -K21 DI_PB DI
/4.3 AII 1.00 /4.3 AIR 1.00 /4.3 DI 1.15

Electrical Diagram
Air main pressure Airend discharge temperature Direction of rotation
Control valve

-K21 DOT 1.00
/4.3 DOT M24
1
2
3
X30
Ext.
-W113
1(+)
2(-)
1
2
-K1
Function:
Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: sensors/actuators SC2 MCS SSK.F-03107.02 10 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
STO STO
9_9463 22 E
Channel 1 Channel 2
-K21 DOR 1.00 -K21 DOR 1.02
/4.3 COM /4.3 COM
-X2 20
7
5
3L+ X5 X5
/2.8
Int. Int.
3L-
/1.8
-X2 PE1 -X2 25 21 23 22 24
13
13.3
SK SFC
6
3
4
5
2
1
ESC OK -W160 7G0,75mm²
ÖLFLEX 150 CY
Operating Manual
/3.7 BN
Annex
-T1
/3.7 WH
1
2
3
4
34
10
11
9
28
69
5
6
7
8
16
17
-T1
+10 V 0 V AI0+ AI0- DI AI1+ AI1- U24V GND DI DI0 DI1 DI2 DI3 DI4 DI5
OUT COM2 COM1
ON
OFF
RDY 64 7
Electrical Diagram
Frequency converter AI 0/1 5

32 6 4
16 5 3
1 2
/1.5 SINAMICS CU240E-2 BF 8 4 2
4 3
RS-485
T1.0 1
I U motor running 2 2
BUS ADDRESS
SAFE 1 1
IN 0,5A 0 - 20 mA PTC/KTY Bus termination

-W255 LiYCY
+24V 0V AO0+ AO0- + - AO1+ AO1- NC NO COM NO COM NC NO COM 2x0,23mm²

31
32
12
13
14
15
26
27
18
19
20
21
22
23
24
25 -T1
2
1
-W162 3G0,75mm²
ÖLFLEX 150 CY
2L+ -X2 2 -X2 1
/3.5 -T1
4
-X2
A1
-K53
A2
2L- -X2 02 -X2 04 -X2 01

/3.5
14 11
/7.4 12
Function: Volt-free contacts

Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Binary inputs / outputs FC SC2 MCS SSK.F-03107.02 10 Bl.
113
114
1 2 3 4 5 6 7 8
13
13.3
Volt-free contacts
SK SFC
User's connection
Operating Manual
Annex
14
12
-K53
/6.5
11
Electrical Diagram
15
16
17
-X11 -X11 -X11

max. 250V AC/6A
24V DC/2A
All non-designated conductors

1,5mm² orange 500V 70°C
Function: Compressor motor running

Group of functions:
a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Volt-free contacts SC2 MCS SSK.F-03107.02 10 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
Inputs/outputs for use by others Possible connections for AII 1.02
4-wire connection
Example connections 2-wire connection
L+ L-
digital inputs, User's connection ?

?
18V DC/7mA 4...20mA 4...20mA
max. cable length 100m Pt100
out - - +
13
13.3
SK SFC
Operating Manual
Int. Int. Int. Int. Int. Int. Int. Int.
Annex
2
8
3
9
4
5
6
1
2
3
1
2
3
1
2
10
11
12
X8 X8 X8 X8 X8 X6 X6 X7
-K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 AII_PA AII GND -K21 AII_PA AII GND -K21 AIR_A AIR_B
DI 1.09 DI 1.10 DI 1.11 DI 1.12 DI 1.13 AII 1.02 AII 1.02 AIR 1.03
Electrical Diagram
*** *** *** Remote ON/OFF ** load/idling ** 4-20mA 4-20mA, 18V DC Pt100
Ri = 200Ω Ri = 200Ω
analog inputs, User's connection


7
5
4
2
10
11
X3 X3 X3 X3 X3 X3
-K21 -K21 -K21 -K21 -K21 -K21
DI_PA DI 1.01 DI 1.03 DI 1.04 DI_PA DI 1.06
*** *** *** ***
Relay outputs, User's connection digital outputs, User's connection

max. 250V AC/24V DC, 1A 24V DC/0,2A
max. cable length 100m max. cable length 30m
Control ON ** ALARM ** Compressor motor running ** *** ***

-K21 DOR 1.05 -K21 DOR 1.06 -K21 DOR 1.07 -K21 DOT 1.01 -K21 DOT 1.02
DOT M24 DOT M24
8
6
** Pre-allocated
2
1
5
4
8
7
7
5
X9 X9 X9 X4 X4
Int. Int. Int. Int. Int. *** Available for use

a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: inputs/outputs SC2 MCS SSK.F-03107.02 10 Bl.
115
116
1 2 3 4 5 6 7 8
diagram 1
primary L1/L2
0
380V
400V
420V
-T11 primary Power connection
-X11 PE2 L1 L2
400V 0 400V
13
0
380V 0 380V
13.3
230V
SK SFC
230V
secondary
L02
-F11:5
Operating Manual
Annex
Electrical Diagram
diagram 2
primary

L1
L2
-T11 Power connection 1-2
1
31
32
33
34
35
36
37
38
2
-X11 PE2 Jumper
primary between:
460V 32-36
440V 32-37
0
0
115V
115V
L02
-F11:5
230V
secondary

a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: transformer diagrams SC2 MCS SSK.F-03107.02 10 Bl.
9_9463 22 E
1 2 3 4 5 6 7 8
9_9463 22 E
fig. 1: Handling: Control line terminal fig. 10: Feed line connection
13
13.3
SK SFC
Operating Manual
Annex
Electrical Diagram
fig. 2: Handling: Supply terminal

a Geprüft Geiger
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Handling: Terminals / Feed line connection SC2 MCS SSK.F-03107.02 10 Bl.
117
118
-W280****
2
4
PE
1L1
1L2
1L3
PE2
Connection number
internal
Destination
13
-R11
Mounting plate
-X11
-R1
-F11
-R1
-F11
-R1
13.3
SK SFC
Location
/6.6
/6.7
/1.4
/6.6
/1.4
/1.4
/1.2
/1.2
/1.2
/1.2
/1.4
/1.4
/1.4
/1.4
/1.4
/1.4
Wire link
Operating Manual
Annex
Terminal legend
total 4 Terminals
total 12 Terminals
Terminal strip
Link
Terminal strip: -X0

Terminal number
SES
SES
SES
SES
PE3
PE3
PE2
PE2
PE1
PE1
U1
U1
V1
V1
W1
W1
Electrical Diagram
Terminal strip: -screen rail FC

PE
Connection number
external
Destination
-T1
-T1
-T1
-T1
-R1
Unit frame
-supply
-supply
-supply
-supply

-W160 7G0,75mm² ÖLFLEX 150 CY
-W211 ****
-W255 LiYCY 2x0,23mm²
-s.b.c. **
** See operating manual for **** performance-related components,
supply cable cross-section see: Equipment parts list

a Geprüft Geiger
H Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: screen rail FC, Volt-free contacts -X0 SC2 MCS KSK.F-03107.02 2 Bl.
9_9463 22 E
119 SK SFC 9_9463 22 E
Rotary screw compressor Operating Manual
c
a
b
Destination Destination
Cable identification Terminal strip Cable identification
internal external
H Änderung
Link
Location
Wire link
Datum
Terminal legend
Terminal number
Connection number
Connection number
Name
-W72 2x1mm² 500V 70°C
Norm
Datum
Geprüft
Bearbeiter
Terminal strip: -X2

total 18 Terminals
Geiger
1
-T1 25 1 /6.6
19.11.2018
01 /6.5 -K53 A2
Taubmann/Seubert
2 /6.2
02 /6.2
3 /3.4 -T21 +
03 /3.4 -T21 -
2
Ersatz durch:
-T1 24 4 /6.5 -K53 A1

04 /6.4
1
-T1 9 20 /6.5 -S5 11

-T1 28 21 /6.5 -K55 A2
-T1 16 22 /6.6 -K21-X5 7
-T1 69 23 /6.5
-T1 17 24 /6.6 -K21-X5 5
3 4 2 5 1 6
-T1 34 25 /6.4
4) Compressor motor running
Ersatz für:
-S1 31 26 /2.6 -S5 12
-S1 32 27 /2.6 -K21-X5 9
Volt-free contacts, User's connection
PE1 /6.3
PE1
Terminal strip: -X11
total 20 Terminals
1 /2.4 s.b.c.
Ursprung:
-T11 01 /2.4 s.b.c.
-F11 6 2 /2.3
02
-T21 L1 3 /2.5 -S1 11
-T21 N 03 /3.2
4 /2.5 -S1 12
, 04 /2.2 -M7.2 N
-K55 14 5 /1.6
05 /1.6 -M7.1 N
-K55 11 6 /1.6 -M7.1 L1
7 /1.7 -M7.2 L1
Terminal schedule
Control cabinet door PE1 /1.6 -M7.1 PE
Terminal strip -X2,-X11

GNYE = green/yellow
. PE1 /2.2 -K21-X4 1

-T11 PE PE2 /2.2 -M7.2 PE
Compressor SK SFC
-X0 PE1 PE2 /1.2 -T21 -

PE3 /2.4 s.b.c.
-K53 15 11 /7.4 4)
-K53 16 12 /7.4 4)
-K53 17 14 /7.5 4)
SC2 MCS
+
=
KSK.F-03107.02
page
2
2
Bl.
Electrical Diagram 13.3
Annex 13
120
1 2 3 4 5 6 7 8
420
-K53,-K55
13
-X2 -X11
13.3
-T21
SK SFC
Operating Manual
Annex
-F11 -T11
Electrical Diagram
940

-T1
-R11
PE
V1
U1
PE
PE
PE
W1
-X0
-R1
c Datum 19.11.2018 Component layout =

a Geprüft Geiger
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Mounting plate SC2 MCS ASK.F-03107.02 1 Bl.
9_9463 22 E

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DESALINATED WATER SUPPLY FOR

SPENCE GROWTH OPTIONS PROJECT

Doc. Nº: SGO-NPIW-EXE-GNR-GFE-01038

IOM MANUAL Doc. SGO-NPIW-EXE-GNR-MFE-01038-A

B 21/01/2020 FINAL DOCUMENT FOR FOR APPROVAL

TEDAGUA Doc. No.: SGO-NPIW-EXE-GNR-MFE-01038-A

B 21/01/2020 FINAL DOCUMENT FOR APPROVAL S.CARVAJAL J.VASQUEZ J.VASQUEZ

A 27/08/2019 Issue for Review S.CARVAJAL J.VASQUEZ J.VASQUEZ

Rev. Date Description Prepared Checked Approved

Rotary screw compressor

COMPRESSORS MODEL ASK40SFC – DESAL PLANT Air System

1 Regarding this document

Operating Manual Rotary screw compressor

4 Design and Function

Operating Manual Rotary screw compressor

9 Fault Recognition and Rectification

Operating Manual Rotary screw compressor

Operating Manual Rotary screw compressor

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

Operating Manual Rotary screw compressor

Operating Manual Rotary screw compressor

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

Operating Manual Rotary screw compressor

Tab. 55 Other faults and remedies .......................................................................................................... 60

Operating Manual Rotary screw compressor

1 Regarding this document

1.2 Further documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

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

Operating Manual Rotary screw compressor

1.4.2 Potential damage warnings

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

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alert notes and their symbols

Operating Manual Rotary screw compressor

Further information Further subjects are introduced here.

Operating Manual Rotary screw compressor

➤ Enter here the nameplate data as a reference:

Option Option code Provided?

Operating Manual Rotary screw compressor

Option Option code Provided?

ASK 28 ASK 34 ASK 40

2.5 Ambient conditions

Tab. 7 Ambient conditions

Operating Manual Rotary screw compressor

Fig. 1 Maximum relative humidity of intake air

ASK 28 ASK 34 ASK 40

Tab. 8 Overview Ventilation (50Hz)

ASK 28 ASK 34 ASK 40

Tab. 9 Overview Ventilation (60Hz)

Operating Manual Rotary screw compressor

Activating pressure [bar] of the relief valve at 50 Hz mains frequency:

Maximum working over‐ ASK 28 ASK 34 ASK 40

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

Activating pressure [bar] of the relief valve at 60 Hz mains frequency:

Maximum working over‐ ASK 28 ASK 34 ASK 40

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

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

Operating Manual Rotary screw compressor

Fig. 2 Flow rate and regulating range

2.8.1 Rated voltage 400 V / 3 / 50 Hz

pNloc [bar] ASK 28 ASK 34 ASK 40