Manual Kaeser CSDX T Compress Translate

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User manual
Screw compressor
CSDX T SIGMA CONTROL 2

9_9519 02 R
Manufacturer:
KAESER COMPRESSORS
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SCSDX 2.02 ru SBA-SCREWS-T-SC
/ KKW / SSC 2.02
20120417 134352
Content
1 To this document
1.1 How to handle the document .......................................................... .................................. 1 1.2
Additional Documents .................. ................................................. ............................... 1 1.3
Copyright ............................... ................................................. .................................................... 1
1.4 Symbols and conventions ... ................................................. .................................. 1 1.4.1
Warning instructions .................. ................................................. ...... 1 1.4.2 Warnings for
damage to property .................................................... 2 1.4.3 Additional information and
symbols .......................................................... ................. 3
2 Specifications
2.1 Rating plate ............................................................... ................................................. ..... 4 2.2
Options .......................................... ................................................. .................................. 4 2.3
Weight .............. ................................................. ................................................. .................. 5 2.4
Temperature ............................... ................................................. .................................... 5 2.5
Ambient conditions .......... ................................................. .................................................. 5 2.6
Ventilation ....... ................................................. ................................................. .......... 6 2.7
Pressure ..................................... ................................................. .................................. 6 2.8
Performance .............. ....................... ................................................. .................................. 7 2.9
Recommended cooling oils .............................. ............................................................. 7 2.10
Amount of coolant to be filled oils ................................................. ......................... 10 2.11 Motors
and power .......................................... ................................................. .............. 11 2.11.1 Compressor
motor ............................... ................................................. ... 11 2.11.2 Fan
motor .............................................. .................................................... 12 2.11.3 Fan
motor . ................................................. .................................. 12 2.12 Sound emission
[dB(A)] ....... ................................................. .................................. 13 2.13 Electrical
supply .................. ................................................. ............. ........................... 13 2.14 Electrical
connection data .............................. ............................................... 14 2.14.1 Mains frequency: 50
Hz ... ................................................. ............................................... 14 2.14.2 Network
frequency: 1000 m ... ................................................. .................................... 15 2.15 Water
cooling .................. ................................................. .................................................... 16 2.15.1
Water cooling (plate heat exchanger) .................................. 17 2.15.2 Water cooling (tube
heat exchanger) ...... .................................. 19 2.16 Heat recovery system ..................................
19 ................................................. .............................. 20 2.16.1 Preparation for an external heat
recovery system .................. ....................... 20 2.16.2 Internal heat recovery
system .................................. .................... ................................. 21 2.17 Refrigeration
dryer .............................. ................................................. ......................... 22
3 Safety and liability
3.1 Fundamental information .......................................................... ..................................................
24 3.2 Intended use ..... ................................................. .................................... 24 3.3 Improper
use .......... ................................................. ......................................... 24 3.4 User
responsibility .................................. ................................................. .............. 25 3.4.1 Compliance
with statutory regulations and generally recognized rules .................. 25 3.4.2 Determination
of personnel .................. ................................................. ............... 25 3.4.3 Compliance with
the terms of technical examination and the rules of
accident prevention .............................................................................. ..................
3.5 Hazards .............................................. ................................................. ....................... 26 3.5.1
Safe handling of hazards .................................. ....................... 26 3.5.2 Safe use of the
machine .............................. ................................................. 29 3.5 .3 Organizational
arrangements ............................................... ......................... 31 3.5.4 Hazardous
areas .................. ................................................. .............................. 31 3.6 Safety
devices .................. ................................................. ................................. 32 3.7 Safety
signs .............................................. ................................................. .................................. 32 3.8 In
an emergency .......................... ......................................... .................................................... 34 3.8.1
Correct actions in the event of a fire ... ................................... 34
Screw Compressor Instruction Manual

9_9519 02 R CSDX T SIGMA CONTROL 2 i
Content
3.8.2 Remedy for injury caused by refrigerant oil .............................. 34 3.8.3 Remedy for injury
or poisoning caused by refrigerant .......................... ..................... 35 3.9
Warranty .......................................... ................................................. .................................. 35 3.10
Environmental protection .............. ................................................. ................................... 36
4 Design and principle of operation 4.1
Enclosure .............................................................. ................................................. ..................................
37 4.2 How the machine works .................. ................................................. .............................. 37 4.2.1
Refrigeration dryer .................. ................................................. ........................... 39 4.2.2
Potential-free contacts .................. ................................................. ........ 39 4.3
Parameters .......................................... ................................................. .............................. 39 4.3.1
Screw-on machine feet .............................. ................................................. 39 4.3.2 Water
cooling ............................................... ............................................... 40 4.3.3 Filter mat for
cooling air ....................................................... 40 4.3.4 Heat recovery system
heat ................................................................ .............................. 41 4.4 Operating modes and
types of control .............................. ................................................. ..... 42 4.4.1 Operating modes of
the machine .............................. ......................................... 42 4.4.2 Types of
regulation .. ................................................. ............................................... 43 4.5 Types of
refrigeration dryer control ............................ ................................................. .............. 44 4.6 Safety
devices .................................. ................................................. 45 4.7 SIGMA CONTROL 2 control
panel .............................................. ......................... 46
5 Installation and operating conditions
5.1 Safety precautions ............................................................... ............................... 50 5.2 Conditions
at the place of installation .............. ................................................. .............................. 50 5.2.1
Determining the installation location and distances .................. ............................................... 50
5.2.2 Ventilation of the engine room .................................. .............................................. 51 5.2.3
Designing the exhaust ventilation duct .............................. 51 ...................................................
52 5.3 Operation of the machine connected to the compressed air network .......... ......................................... 52
6 Installation
6.1 Safety precautions ............................................................... ............................................... 53 6.2
Reporting damage in transit .............................. 53 .............................. 54 6.3 Connecting the machine
to the compressed air network .................. ................................................... 54 6.4 Electrical
connection .................................................... ................................................................. 55 6.4.1
Refrigeration dryer: matching with mains voltage .................................... 55 6.5 Connecting the
condensate drain .......... ................................................. .... 56 6.6
Options .......................................... ................................................. .................................. 57 6.6.1
Fixing the machine .................. ................................................. .............................................. 57
6.6.2 Connecting the cooling water system .............. 57 ...................... ..... 57 6.6.3 Connecting
the heat recovery system ..................................... ............ 58
7 Commissioning
7.1 Safety precautions ............................................................... ............................... 60 7.2 Before
commissioning .............................. ................................................. .............................................. 61 7.3
Monitoring compliance with installation and operation requirements .............................. .................................
61 7.4 Installing the magnetic starter .................................. ................................................. ..... 62 7.5
Adjusting the motor circuit breaker .............................................. .................................. 62 7.6 Filling
cooling oil into the compressor block .................................. .............................. 63 7.7 Switching PART
LOAD control on and off .............................. .......... 64 7.8 Switching on the machine for the first
time .............................. ................................................. ...... 65 7.9 Setting the set network
pressure .............................................. ...................................... 66 7.10 Changing the display
language .................................................. ............................................... 66
8 Operation 8.1
Switching on and off .................................................... ................................................. 67 8.1.1
Switching on ............................................... ................................................. .......... 67

ii CSDX T SIGMA CONTROL 2 9_9519 02 R
Content
8.1.2 Shutdown ............................................... ................................................. ...... 67 8.2

Switching on and off in an emergency .................................................... .................................. 68
8.3 Switching on and off by remote control .............................. .............................. 68 8.4 Switching
on and off with the timer .............................. ............................................................. 69 8.5 Operating
messages . ................................................. ................................................. 70 8.6 Acknowledging
fault and warning messages .......... ................... 70
9 Error recognition and elimination
9.1 Basic information .................................................................. .................................................. 73
9.2 Other faults .......... ................................................. ................................................. 73
10 Maintenance
10.1 Safety precautions ............................................................... ............................................... 75
10.2 Compliance with maintenance intervals ............................... ................................................. ..............
76 10.2.1 Documentation of maintenance work .................................................. ............ 76
10.2.2 Resetting the maintenance hour counter 76
position ................................................. .................................................. .....
10.2.3 Regular maintenance work ............................................................... ...................... 76

10.2.4 Coolant oil change intervals .............................................. ....................................... 78
10.2.5 Regular maintenance work .............................. ................................................... 79
10.3 Cleaning or replacing the control cabinet filter mat ... .............................. 79 10.4 Radiator
maintenance .............................................. ................................................. .... 80 10.5 Maintenance
of the cooling water system .................................................. .............................. 81 10.6 Cleaning
or replacing the cooling air filter mat .................................. 82 10.7 System maintenance heat
recovery .............................................................. ...................... 83 10.7.1 External heat recovery
system .............................................. .............................................. 83 10.7.2 Internal heat
recovery system .............................. 83 ......... .................................... 83 10.8 Replacing the
air filter .......... ................................................. .............................. 83 10.9 Engine
maintenance .................................. ................................................. .................................... 84 10.10
Checking the clutch .............................................. ................................................. .............. 85 10.11
Checking the safety valve .............................. 85 .................................................................. 86 10.12
Checking the safety shutdown at elevated temperatures .. ...................... 87 10.13 Checking the
cooling oil level .................................. ............................................... 88 10.14 Depressurizing the
machine ...... ................................................. .................................. 88 10.15 Topping up the cooling
oil .............. 88 ................................................. ......................... 90 10.15.1 Pressure relief out of the
car ............................................... .............................. 91 10.15.2 Topping up the cooling oil
and carrying out a test run .......... ......... 92 10.16 Changing the cooling
oil .................................. ................................................. 93 10.17 Replacing the oil filter
element .............................................................. .............................. 98 10.18 Replace the oil
separator element .............................................. .............................. 99 10.19 Maintenance of the
refrigeration dryer .................. ................................................. .......... 101 10.19.1 Cleaning the
condenser .................................. ................................................. .. 102 10.19.2 Maintenance
of the condensate drain .................................................................. ...... 102 10.20
Documentation of preventive maintenance and maintenance work ............................... 104
11 Spare parts, operating fluids, maintenance
11.1 Pay attention to the rating plate .................................................. .................................. 105 11.2
Ordering spare parts and consumables .................................. ................... 105 11.3 KAESER AIR
SERVICE .................... ................................................. ........................... 105 11.4 Coordinates of
service centers ....................... ................................................. .......... 106 11.5 Spare parts for
maintenance and repair .............................. ........................... 106
12 Decommissioning, storage and transport
12.1 Decommissioning ............................................................... ................................................. ...
115 12.2 Packaging ............................................... ................................................. ...............................
115 12.3 Storage .................... ................................................. ................................................. .. 116

9_9519 02 R CSDX T SIGMA CONTROL 2 iii
Content
12.4 Transport .................................................................. ................................................. .......... 116

12.4.1 Safety .......................................... ................................................. .................................
116 12.4.2 Transporting the machine with a forklift ................................. 116 12.4 .3
Transporting the machine with a crane ....................................................... ...... 117 12.5
Disposal .......................................... ................................................. ........................... 117
13 Appendix 13.1
Technological scheme of pipelines and tools (R+I - scheme) .............................................. 119 13.2
Technological scheme of pipelines and tools (R + I-diagram) 125
PARTIAL LOAD control ............................................................... .................... 13.3
Dimensional drawing .............................. ................................................. ........................... 131 13.4
Wiring diagram .................. ................................................. ................................. 135

iv CSDX T SIGMA CONTROL 2 9_9519 02 R
List of drawings
Rice. 1 Maximum relative humidity of intake air .............................................. 6 fig. 2 Location of

safety signs ............................................................... ......................................... 32 Fig. 3 Body
image .................................................................. ................................................. ............. 37 Fig. 4
Machine image ............................................... ................................................. .............. 38 Fig. 5
Refrigeration dryer .................................................. ................................................. ................... 39
Fig. 6 Screw-on machine support ....................................................... ......................................... 39
Fig. 7 Water cooling (option K2) .............................................. ................................................. 40
Fig. 8 Water cooling (option K9) .............................................. ................................................. 40
Fig. 9 Filter mat for cooling air (option K3) .............................................................. ..... 41 Fig. 10
Internal heat recovery system (option W2/W3) .............................................................. ............... 42
Fig. 11 Button image ............................................... ................................................. ................ 46 Fig.
12 Overview of indicators ............................................... ................................................. ..................
47 Fig. 13 RFID reader .............................................................. ................................................. 48
Fig. 14 Installation recommendations, dimensions [mm] .............................................. .................................
51 Fig. 15 Air line .................................................. ................................................. ......................... 54
Fig. 16 Condensate drainage system, dimensions [mm] .............................................. .................................
56 Fig. 17 Connecting the water cooling system .......................................................... .......................
57 Fig. 18 Connecting the heat recovery system ............................................................... ...........................
59 Fig. 19 Filler hole on the inlet valve .................................................. ................................. 63 Fig.
20 Clutch ............................................................... ................................................. .................... 64
Fig. 21 PART LOAD control: shut-off valve positions .................................................. 65 fig. 22
Switching on and off ............................................... ................................................. ........ 67 Fig. 23
Shutdown in an emergency .......................................................... ................................................. 68
Fig. 24 Switching on and off with remote control .............................................................. ....................
69 Fig. 25 Switching on and off with the timer .............................................................. .........................
70 Fig. 26 Message acknowledgment .............................................................. ..............................................
71 Fig. 27 Switch cabinet ventilation ............................................................... .................................
80 Fig. 28 Cleaning the heatsink ....................................................... ................................................. ...........
81 Fig. 29 Cooling air filter mat .............................................................. .................... 82 Fig. 30 Air
filter maintenance ............................................................... ................................... 84 Fig. 31 Engine
maintenance .......................................................... ................................................. 85 Fig. 32
Checking the clutch ............................................................... ................................................. ... 86
Fig. 33 Checking the cooling oil level .............................................................. ....................................
88 Fig. 34 Depressurizing the machine .................................................. ................................................. .....
89 Fig. 35 Adding cooling oil .................................................................. .................................................
91 Fig. 36 Coolant oil change, oil separator .............................................................. .........................
94 Fig. 37 Coolant oil change, oil cooler .............................................................. .................. 96 Fig.
38 Coolant oil change, compressor unit .................................................................. ...........................
96 Fig. 39 Cooling oil change, heat recovery system .............................................................. ...... 97
Fig. 40 Changing the oil filter .................................................. ................................................. ..... 99
Fig. 41 Replace oil separator element .............................................................. ......................... 100
Fig. 42 Refrigeration dryer .................................................. ................................................. ...................
101 Fig. 43 Check condensate drain .................................................................. ..................................
102 Fig. 44 Maintenance of the condensate drain .................................................................. ....................
103 Fig. 45 Transport by forklift .................................................................. ................................. 116
Fig. 46 Transport by crane .................................................................. ................................................. 117

9_9519 02 R CSDX T SIGMA CONTROL 2 in
List of drawings

we CSDX T SIGMA CONTROL 2 9_9519 02 R
List of tables
Tab. 1 Hazard levels and their meaning (danger to personnel) .............................................................. ..... 1 tab. 2 Degrees of danger and
their meaning (property damage) .............................................................. ........... 2 Tab. 3 Rating
plate ....................................................... ................................................. ............... 4 Tab. 4
Options .................................................. ................................................. ............................................... 4 Tab. 5 Machine
weight ............................................... ................................................. ............................... 5 Tab. 6
Temperature .................................................. ................................................. ...................... 5 Tab. 7 Ambient
conditions ............................................... ................................................. .............. 5 Tab. 8
Ventilation .................................................. ................................................. ............................... 6 Tab. 9 Relief valve setting pressure
(50Hz) .............................................................. .. 6 Tab. 10 Relief valve setting pressure (60Hz) .............................................................. ..
7 Tab. 11 Performance (50 Hz) ............................................... ................................................. ...... 7 Tab. 12 Performance (60
Hz) ............................................... ................................................. ...... 7 Tab. 13 Recommended cooling
oils .................................................................. ............................... 8 Tab. 14 Recommended cooling oils (for the food
industry) .............................................. 8 Tab. 15 Recommended cooling oils (snow gun machines) ..................................................................
9 Tab. 16 Amount of cooling oil to be filled (option K1) .............................................................. ........ 10 Tab. 17 Amount of cooling oil to be
filled (option K2) .............................................................. ........ 10 Tab. 18 Amount of cooling oil to be filled (option
K9) .............................................................. ........ 10 Tab. 19 Amount of cooling oil to be filled (option
W1) .............................................................. ....... 11 Tab. 20 Amount of cooling oil to be filled (option
W2) .............................................................. ....... 11 Tab. 21 Amount of cooling oil to be filled (option
W3) .............................................................. ....... 11 Tab. 22 Compressor motor (50Hz) ............................................... ..............................................
11 Tab. 23 Compressor motor (60Hz) ............................................... ................................................. .. 12 Tab. 24 Fan motor (option
K1) .............................................. ............................................... 12 Tab. 25 Fan motor (option K2/K9;
50Hz) .............................................. ................................... 12 Tab. 26 Fan motor (option K2/K9;
60Hz) .............................................. ................................... 13 Tab. 27 Sound emission
[dB(A)] .......................................... ................................................. .......... 13 Tab. 28 Connection characteristics 200V/
3/50Hz .................................................. ................................. 14 Tab. 29 Connection characteristics 230V/
3/60Hz .................................................. ................................. 16 Tab. 35 Cooling water temperature
(ÿT=10K) .................................................. ................................. 17 Tab. 36 Cooling water temperature
(ÿT=30K) .................................................. ................................. 17 Tab. 37 Specification: Heat exchanger (option
K2) .............................................. ................................. 18 Tab. 38 Cooling water
quality ............................................................... ................................................. 18 Tab. 39 Cooling water temperature
(ÿT=10K) .................................................. ................................. 19 Tab. 40 Cooling water temperature
(ÿT=30K) .................................................. ................................. 19 Tab. 41 Specification: heat exchanger (option
K9) ............................................... ................................. 19 Tab. 42 Cooling water
quality ............................................................... ................................................. .20 Tab. 43 Heat output (option
W1) .................................................. ................................................. .20 Tab. 44 Cooling water
quality ............................................................... ................................................. 21 Tab. 45 Specification: Heat exchanger (options W2/
W3) .............................................. ............................... 21 Tab. 46 Heat output (options W2/
W3) .................................................. ............................................... 22 Tab. 47 Volume flow/pressure loss (option
W2) .................................................. ............................... 22 Tab. 48 Volume flow/pressure loss (option
W3) .................................................. ............................... 22 Tab. 49 Refrigeration dryer: Pneumatic
system .................................................... ......................................... 22 Tab. 50 Refrigeration dryer: Refrigerant circulation
system .............................................................. ................ 23 Tab. 51 Terms of technical examination in accordance with the rules of safety
26
operation ................................................. ................................................. .........................

Tab. 52 Dangerous areas ............................................... ................................................. ......................... 31 Tab. 53 Safety
signs ............................................................... ................................................. ................. 33

9_9519 02 R CSDX T SIGMA CONTROL 2 vii
List of tables
Tab. 54 Energy-saving types of regulation ............................................................... ...............................

43 Tab. 55 Operating modes for control type PART LOAD .................................................. 44 Tab. 56
Types of refrigeration dryer control ............................................................... ................................... 45
Tab. 57 Buttons .................................................. ................................................. ...............................
46 Tab. 58 Indicators ............................................... ................................................. ...............................
47 Tab. 59 RFID reader .................................................................. ................................................. 49
Tab. 60 Commissioning after a long period of storage/outage .............................................. 61 Tab. 61
Installation Requirements Checklist .................................................................. ...............................................
61 Tab. 62 PART LOAD control: shut-off valve positions .............................................. 64 Tab. 63
Identification on the machine ............................................... ................................................. .......... 69
Tab. 64 Indication on the remote control ....................................................... .................................... 69
Tab. 65 Identification on the machine ............................................... ................................................. ..........
70 Tab. 66 Miscellaneous faults and remedies .................................................................. ...............................
73 Tab. 67 Regular maintenance work ............................................................... .................................
77 Tab. 68 Coolant oil: change intervals .................................................. .................................... 78
Tab. 69 Regular preventive maintenance ............................................................... ...................................
79 Tab. 70 Registered maintenance work .................................................................. 104 Tab. 71
Spare parts for machine maintenance ....................................................... ......................... 105

viii CSDX T SIGMA CONTROL 2 9_9519 02 R
1 About this document
1.1 How to handle this document
1 To this document
1.1 How to handle the document
The instruction manual is an integral part of the product. It describes the condition of the machine
at the time of delivery from the factory.
ÿ Keep the operating instructions for the entire life of the machine. ÿ Pass on the operating instructions to
each subsequent owner or

user.
ÿ Ensure that all changes are made to the operating instructions. ÿ Enter the data on the rating
plate and the individual features of the machine

tires in the table in section 2.
1.2 Additional documents

Together with the operating instructions, you will receive additional documents: ÿ
Acceptance certificate/operating instructions for the receiver ÿ Declaration of conformity
with the requirements of the applicable directives ÿ Instructions for using SIGMA
CONTROL 2
Missing documents can be ordered from KAESER. ÿ Check the

completeness of the documents and follow the instructions contained therein. ÿ When
ordering additional documents, please be sure to indicate the data of the company
plates.
1.3 Copyright
This operating manual is protected by copyright. Please contact KAESER for questions regarding the use and reproduction
of the documentation. We will be happy to assist you with the appropriate use of the information.
1.4 Symbols and conventions

ÿ Pay attention to the symbols and designations in this manual.
1.4.1 Warning instructions

Warning notes warn of a possible danger to personnel resulting from non-observance of the relevant measures.
The warning notices are divided into three levels of danger, which you can recognize by the signal word:
Signal word Meaning Consequences for non-compliance

DANGEROUS Warns of an imminent danger As a result of severe bodily injury or death
sti

1
9_9519 02 R CSDX T SIGMA CONTROL 2
1 To this document 1.4
Symbols and Conventions
Signal word Meaning Consequences for non-compliance

WARNING Warns of a potentially dangerous situation Warns of a Possible severe injury or death Possible minor injury
potentially hazardous situation
CAREFULLY
Tab. 1 Hazard levels and their meaning (danger to personnel)
Warning notices at the beginning of a section apply to the entire section and all of its subsections.
Example:
DANGER
Types and sources of danger are described here! The possible consequences
are described here if the warning instructions are not observed. The signal word "DANGER" means that failure to
follow these instructions could result in severe bodily injury or death.
ÿ Here are the steps you can take to protect yourself from
dangers.
Warning notices that apply to subsections or instructions for action are given directly in them and their order is numbered.
Example:
1. WARNING! Types and sources
of threatening danger are described here! This describes the possible
consequences if the warning instructions are not observed. The signal word "WARNING" means that failure to follow
these instructions could result in severe bodily injury or death.
ÿ Here are measures that you can take to protect yourself from danger.
news.
2. Read the warning instructions carefully and follow them at all times.
1.4.2 Warnings for property damage

In contrast to warning notices, this is not a danger to personnel.
You can recognize material damage warnings by the signal word:
Signal word Meaning Consequences in case of non-

NOTE Warns of a possible hazardous situation observance Material damage possible
Tab. 2 Danger levels and their meaning (material damage)
Example:

2 CSDX T SIGMA CONTROL 2 9_9519 02 R
1 To this document 1.4
Symbols and Conventions
NOTE
Types and sources of threatening danger are described here! This describes the
possible consequences if the warnings are not followed. ÿ Measures that can be used to prevent property
damage are described here.
ÿ Read the warnings carefully and follow them strictly.
1.4.3 Additional information and symbols

This symbol indicates important information.
Material Here you can find information about special tools, consumables or consumables.
spare parts.
Prerequisite This describes the prerequisites for performing any action. In this case, safety measures can be indicated that will help you avoid
dangerous situations.
Option H1 ÿ This symbol indicates a guide to action consisting of only one step.
If actions are performed in several steps, their order is numbered.
bath.
Information relating to only one option is given an alphanumeric designation (for example: H1 means that this section only
applies to machines with the option of attaching feet to the floor). The alphanumeric designations used in this manual are
explained in section 2.2.
Information about potential problems is indicated by an interrogative

sign.
The supporting text states the reason...

ÿ
... and recommendations for its elimination are given.
This symbol indicates important information or measures to protect the environment.
Additional Information Here draw your attention to the following description of this topic.

CSDX T SIGMA CONTROL 2 3
9_9519 02 R
2 Specifications
2.1 Rating plate
2 Specifications
2.1 Rating plate
On the rating plate you will find the main technical data and the model of the machine.
The rating plate is located on the outside of the machine:

ÿ above the radiator,
or
ÿ on the back of the machine
ÿ Enter the nameplate data here:
Name Meaning
Screw compressor
article number
Serial number
Year of issue
Rated power
Rated engine speed
Maximum overpressure
Ambient temperature
Tab. 3 Rating plate
2.2 Options
The list of possible options is given in the table.
ÿ Indicate optional equipment in the column on availability:
Option Designation In stock?
Partial load control C1

SIGMA CONTROL 2 C3
Screw-on machine feet H1
Air cooling Water cooling K1
K2
(plate heat exchanger)
Cooling air filter mat K3
K9
(tubular heat exchanger)
Power supply to the refrigeration dryer via trans- T2
formatter
Preparation for a heat recovery system W1
Heat recovery system ÿT=25 K W2

2 Specifications
2.3 Weight
Option Designation In stock?
Heat recovery system ÿT=55 K W3
Tab. 4 Options
2.3 Weight
The indicated weight is the maximum weight. The actual weight of the machine depends on
individual equipment.
CSDX 140 CSDX 165
Weight, kg] 2045 2140
Tab. 5 Machine weight
2.4 Temperature
CSDX 140 CSDX 165
Minimum temperature 3 3
switch-on temperature [°C]

Working end theme 65 – 100 65 – 100
compression temperature [°C]
Maximum ultimate 110 110

compression temperature
(automatic protection
shutdown) [°C]
Tab. 6 Temperature
2.5 Ambient conditions

CSDX 140 CSDX 165
Max Height 1000 1000

above sea level in me-
installation space* [m]
Permissible ambient 3 – 45 3 – 45
ambient temperature [°C]
Cooling temperature 3 – 45 3 – 45
supply air [°C]
suction temperature 3 – 45 3 – 45
fresh air [°C]
*
Installation in higher places is only possible after agreement with the manufacturer
Tab. 7 Environment

9_9519 02 R CSDX T SIGMA CONTROL 2 5
2 Specifications 2.6 Ventilation
Rice. 1 Maximum relative humidity of intake air

T Intake air temperature [°C]
H Maximum relative humidity of intake air [%]
2.6 Ventilation
The indicated values are standard values which must not be understated.
reap.
CSDX 140 CSDX 165
Ventilation opening Z see 2,3 / 0,8* 2,7 / 0,8*

figure 14, [m2 ] Exhaust
fan for forced ventilation:
volume flow [m3 /h] at 100 32000 37000
Pa * Option K2/K9 11000* 12000*
Tab. 8 Ventilation
2.7 Pressure
Maximum overpressure: see rating plate
Safety valve set pressure at 50 Hz [bar]:
Maximum operating CSDX 140 CSDX 165

overpressure [bar] 8.5
10 10
12,0 14 14
15,0 16* 16*

2 Specifications
2.8 Performance
Maximum excess CSDX 140 CSDX 165

operating pressure
[bar]
*
China: 15.9 bar
Tab. 9 Relief valve setting pressure (50Hz)
Safety valve set pressure at 60 Hz [bar]:

operating pressure
[bar]
8,5 10 10
12,0 14 14
15,0 16 16
Tab. 10 Relief valve set pressure (60Hz)
2.8 Performance
Productivity [m3 /min] at a network frequency of 50 Hz:

operating pressure
[bar]
8,5 13,7 16,1
12,0 11,6 13,3
15,0 9,7 11,3
Tab. 11 Performance (50Hz)
Productivity [m3 / min] at a network frequency of 60 Hz:

operating pressure
[bar]
8,5 14,0 16,0
12,0 11,6 13,6
15,0 9,4 11,3
Tab. 12 Performance (60Hz)
2.9 Recommended cooling oils

The brand of the filled cooling oil is indicated on the oil separator reservoir next to the
drain pipe.
Information required for ordering cooling oil can be found in section 11.

CSDX T SIGMA CONTROL 2 7
9_9519 02 R
2 Technical data 2.9 Recommended
cooling oils
General purpose cooling oils
SIGMA FLUID
MOL S-460 S-570

Description Mineral oil Silicone-free, synthetic oil
synthetic oil
Area of reception Standard oil for all areas Standard oil for all applications except Standard oil for East and
changes food processing Southeast Asia, optionally
applications other than food
stance.
mindset. use in all
Particularly suitable for machines with
areas except for food processing
Particularly suitable for low a high load. Not allowed for use in East
load machines. and Southeast Asia.
stance.
Particularly suitable for high

load machines.
— — —
Permission to
apply
we
Viscosity at 40 °C 44 mm2 / s 45 mm2 / s 52.8 mm2 / s

(DIN 51562–1) (D 445; ASTM test) (D 445; ASTM test)
Viscosity at 100 6.8 mm2 / s 7.2 mm2 / s 8.0 mm2 / s

°C (DIN 51562-1) (D 445; ASTM test) (D 445; ASTM test)
Temperature 220 °C 238 ÿ 258 ÿ

outbreaks (ISO 2592) (D 92; ASTM test) (D 92; ASTM test)
Density at 15 —
864 kg / m3 0.869 kg / l
°C (ISO 12185) (D 1298; ASTM test)
Temperature ÿ33 °C ÿ46 °C ÿ54 °C

solidification (ISO 3016) (D 97; ASTM test) (D 97; ASTM test)
Ability to —
40/40/0/10 min 15 min
demulsification at (D 1401; ASTM test) (D 1401; ASTM test)
54 °C
Tab. 13 Recommended cooling oils
Cooling oils for the food industry
SIGMA FLUID
FG-460 FG-680
Description synthetic oil synthetic oil
Area of application - Especially for machines used in areas where compressed Especially for machines used in areas where
nia air can come into contact with products compressed air can come into contact with
products
nutrition. nutrition.

2 Technical data 2.9 Recommended
cooling oils
SIGMA FLUID
FG-460 FG-680
Permission to apply USDA H–1, NSF USDA H–1, NSF Approved in packaging industry
Approved in food packaging, food forging, meat and meat
poultry
and
processing
poultry processing industry and other
industries and other industries for food processing. for food processing.
Viscosity at 40 °C 50.7 mm2 / s 70.0 mm2 / s

(D 445; ASTM test) (D 445; ASTM test)
Viscosity at 100 8.2 mm2 / s 10.4 mm2 / s

°C (D 445; ASTM test) (D 445; ASTM test)
Temperature 245 ÿ 245 ÿ

outbreaks (D 92; ASTM test) (D 92; ASTM test)
— —
Density at 15 °C
— —
Temperature for
freezing
Ability to — —
demulsification at 54
°C
Tab. 14 Recommended cooling oils (for the food industry)
Cooling oils for snow gun operation
SIGMA FLUID
PANOLIN HLP SYNTH 46
Description Saturated ester with additives (oil-free) According to OECD criteria biodegradable
position
Application area Specially for machines intended for use with snow guns.
Approval - Viscosity at 40°C
47 mm2 / s
Viscosity at 100 8.1 mm2 / s

°C
Flash point > 210 °C
Density at 15 °C 0.92 g / ml
Pour point Demulsibility at 54 °C –35 °C

—
Tab. 15 Recommended cooling oils (snow gun machines)

2 Specifications
2.10 Amount of cooling oil to be filled
2.10 Amount of cooling oil to be filled

The filling quantity varies depending on the option of the heat recovery system.
For machines with option W1, W2 or W3, additional coolant must be topped up.
waiting oil for the heat recovery system.
Option K1 air cooling
CSDX 140 CSDX 165

Filling quantity 52 52
* [l]
Topping up 5 5
th oil [l]
(minimum - maximum)
*
taking into account the oil poured into the heat recovery system
Tab. 16 Amount of cooling oil to be filled (option K1)
Option K2 Water cooling (plate heat exchanger)
CSDX 140 CSDX 165

Filled quantity 50 50
[l]
Topping up 5 5
th oil [l]
(minimum - maximum)
*
Option K9 Water cooling (tube heat exchanger)
CSDX 140 CSDX 165

Filled quantity 50 50
[l]
Topping up 5 5
th oil [l]
(minimum - maximum)
*

2 Specifications
2.11 Engines and power
ÿÿÿÿÿ W1/W2/W3 Heat recovery system
Option W1 The amount of oil to be added is increased by the amount of cooling oil in the heat exchanger.
mennik and pipelines:
CSDX 140 CSDX 165
Additional amount
the quantity of the poured ma-
sla [l] *
*
Specify the amount of oil to be filled into your heat recovery system
Tab. 19 Amount of cooling oil to be filled (option W1)
Option W2 CSDX 140 CSDX 165
Additional amount 9,0 9,0

sla [l]
Option W3 CSDX 140 CSDX 165
Additional amount 5,6 5,6

sla [l]

2.11.1 Compressor motor
Network frequency: 50 Hz
CSDX 140 CSDX 165
Rated power 75 90
power [kW]
Rated frequency 2978 2980
rotation [min-1]
Degree of protection IP 55 IP 55
Bearing lubrication period 2000 2000

engine kov [h]
The amount of grease
lubrication in the bearing
ke [g] *
h = working hours
*
Enter the data on the nameplate of the motor into the table.
Tab. 22 Compressor motor (50Hz)

2 Specifications
Network frequency: 1000M
CSDX 140 CSDX 165
Rated power 75 90
power [kW]
rotation [min-1]

engine kov [h]
ke [g] *
h = working hours
*
Tab. 23 Compressor motor (60Hz)
2.11.2 Option K1
fan motor
CSDX 140 CSDX 165
Rated power 1,4 1,4

power [kW]
rotation [min-1]

engine kov [h]
ke [g] *
h = working hours
*
Tab. 24 Fan motor (option K1)
2.11.3 Option K2 / K9
fan motor
Network frequency: 50 Hz
CSDX 140 CSDX 165
Rated power 0,12 0,12

power [kW]
rotation [min-1]

2 Specifications
2.12 Sound emission [dB(A)]
CSDX 140 CSDX 165
Tab. 25 Fan motor (option K2/K9; 50Hz)
Network frequency: 1000M
CSDX 140 CSDX 165
Rated power 0,12 0,12

power [kW]
rotation [min-1]
Tab. 26 Fan motor (option K2/K9; 60Hz)
2.12 Sound emission [dB(A)]

Network frequency CSDX 140 CSDX 165
50 Hz 71 / 70* 72 / 71*
1000 m 72 / 71* 73 / 72*
Sound pressure level according to ISO 2151 and the underlying standard
ISO 9614-2, tolerance: ± 3 dB(A) at max.
phenomenon
* Option K2 / K9
Tab. 27 Sound emission [dB(A)]
2.13 Electrical supply

Primary requirements
The machine is designed in accordance with the power supply conditions according to the standard
EN 60204-1 (IEC 60204-1), section 4.3.
Unless otherwise specified by the user, the limit values must be observed.
values described in this standard.
In addition, we recommend that an agreement be made between the consumer and the supplier on the basis of
new standard EN 60204-1, Annex B.
A symmetrical three-phase network is required for the electrical connection of the machine.
In a symmetrical three-phase network, the voltage and phase shift between the individual phases are the same
nakova.
The machine may only be operated from a three-phase network with an earthing system of the type
TN or TT.
It is not allowed to connect to a network with an IT type earthing system without additional equipment.
activities (control of insulation resistance, etc.).
The machine is designed for operation from the mains supply inside industrial
objects separated from the public power supply network by means of a transformer
or a generator.
The power cable inside the cabinet should be laid as short as possible.

2 Technical data 2.14
Electrical connection data
If it is necessary to connect external sensors or communication cables to the machine, use shielded cables and EMC-compliant
cable glands.
Additional requirements
Requirements for a three-phase network for a machine equipped with: ÿ
refrigeration dryer with power supply through a transformer
This machine may only be connected to a three-phase network with a TN or TT type earthing system with an earthed star point.
This machine must not be connected to a three-phase, phase-to-earth circuit as this may result in dangerous overvoltage.
It is not allowed to connect to a network with an IT earthing system without additional measures (insulation resistance monitoring,
special version of the frequency converter, etc.).
Additional Information See the wiring diagram in section 13.4 for more information on the electrical connection.
2.14 Electrical connection data

The following cross-sections of the supply cables (copper stranded cable) and fuses (fuse, service class gL) are calculated in
accordance with DIN VDE 0100-430 (IEC 60364-4-43 and IEC 60364-4-473) and DIN VDE 0298-4 for ambient temperature 30 °C
and installation method C.
ÿ For other operating conditions, check the cross section of the supply cables and adjust
in line.
Other operating conditions include, for example:
ÿ high temperature
ÿ Other wiring method ÿ Wiring length
>50m
2.14.1 Mains frequency: 50Hz
Rated voltage: 200V±10%/3/50Hz
CSDX 140 CSDX 165

— —
Input fuse [A] Power cable [mm2 ]
Current consumption [A]
— —
— / —* — / —*
* Option K2 / K9
Tab. 28 Connection characteristics 200V/3/50Hz

2 Specifications
2.14 Electrical connection data
CSDX 140 CSDX 165
Input fuse — —
where [A]
— —
Power cable [mm2 ]

Current consumption [A] — / —* — / —*
* Option K2 / K9
CSDX 140 CSDX 165
Input fuse 160 200

where [A]
Power cable [mm2 ] 4x70 4x95
Current consumption [A] 158 / 154* 179 / 175*
* Option K2 / K9
2.14.2 Network frequency: 1000M
CSDX 140 CSDX 165
Input fuse 315 400

where [A]
Power cable [mm2 ] 2x 4x70 2x 4x95
* Option K2 / K9
CSDX 140 CSDX 165
Input fuse 200 200

where [A]
Power cable [mm2 ] 4x95 4x120 / 4x95 *
* Option K2 / K9

2 Specifications
2.15 Water cooling
CSDX 140 CSDX 165
Input fuse 160 200

where [A]
Power cable [mm2 ] 4x70 4x95
* Option K2 / K9
CSDX 140 CSDX 165
Input fuse 160 200 / 160*

where [A]
Power cable [mm2 ] 4x70 4x95 / 4x70*
* Option K2 / K9
2.15 K2 / K9 option
Water cooling
If a leak occurs, the cooling oil may enter the cooling water.
ÿ The drinking water must only be heated with a suitable heating
lobe exchanger.
When an antifreeze agent is added to the cooling water, the specific

thermal conductivity of the cooling water and the required flow volume.
ÿ To ensure the correct operation of the cooling system, contact the authorized
called KAESER Service.
ÿ To prevent malfunctions due to rust, leave
limescale and contamination, the specified requirements for cooling must be complied with.
giving water
A prerequisite is the implementation of measures for filtering and preparing
cooling water supply.
Addresses of organizations performing water quality analysis and supplying devices
for water treatment can be obtained from KAESER.
The following design options are possible:

ÿ Option K2: water-cooled with plate heat exchanger, section 2.15.1
ÿ Option K9: water-cooled with tube heat exchanger, section 2.15.2

2 Specifications
2.15 Water cooling
Open cooling system
An example of an open cooling system is an open cooling circuit.

cooling tower where cooling water is cooled by evaporation. Because part of the water is used
steamed, it must be constantly added. The consequence of evaporation is the end
contaminants in the cooling water, contamination can be aggravated
due to the contact of water with the surrounding air. When topping up cooling water,
blowing to comply with the requirements for cooling water.
Closed cooling system
In a closed cooling system, the cooling water does not come into contact with the atmospheric air.
hom. Therefore, the ingress of pollution from the air and the enrichment of oxygen are excluded.
Flow cooling system
The flow cooling system is an open cooling system. Tap water

yes from underground sources and open reservoirs passes through the cooling system one
once.
Additional Direction of flow, dimensions and location of the connection fitting can be found on the diagram.
information barite drawing in section 13.3.
2.15.1 Option K2
Water cooling (plate heat exchanger)
The primary circuit of the heat exchanger is connected to the machine. The given data is relative
are connected to the secondary circuit of the heat exchanger.
2.15.1.1 Technical data
Cooling water temperature increase by 10 K:
CSDX 140 CSDX 165
Maximum allowable 40 40
May temperature at
inlet [°C]
Volume flow [m3 /h] 7,4 8,5
Pressure loss [bar] 0,5 0,5
Tab. 35 Cooling water temperature (ÿT=10K)
CSDX 140 CSDX 165
May temperature at
inlet [°C]

2 Specifications
2.15 Water cooling
Heat exchanger specification:
CSDX 140 CSDX 165
Material 1.4401 1.4401
Solder Copper (Cu) Copper (Cu)

Maximum excess 10 10
operating pressure
[bar]
May temperature at
course [°C]
Max volume- 23 23
flow [m3 /h]
Unsuitable coolants Salty water

pending funds The use of aqueous solutions is only permitted by agreement
cooperation with KAESER
Tab. 37 Specification: Heat exchanger (option K2)
2.15.1.2 Cooling water quality
Properties/contained substances closed system open system

cooling cooling
pH value Total 7,5–9,0 7,5–9,0
hardness [°dH] 0–20 0–20
Carbonate hardness [°dH] Chlorides <20 <4
(Cl) [mg/l] <100 <100
Dissolved iron (Fe) [mg/l] Sulphates <0,5 <0,2
(SO4 ) [mg/l] <300 <300
HCO3 /SO4 ratio >1 >1
Conductivity [µS/cm] 10–800 10–1500
Ammonium (NH4 + ) [mg / l] <1 <1
Dissolved manganese (Mn) [mg/l] <0,1 <0,1
Glycol [%] 20–40 —
Solids (particle size) [mm] <0,1 <0,1
Microbial number [CFU*/ml] 10 000 10 000
Particulate matter [ppm] <20 <20

(undissolved)
* CFU: number of colony forming units
Tab. 38 Cooling water quality

2 Specifications
2.15 Water cooling
2.15.2 Option K9
Water cooling (tube heat exchanger)
The primary circuit of the heat exchanger is connected to the machine. The given data is relative
are connected to the secondary circuit of the heat exchanger.
2.15.2.1 Technical data
CSDX 140 CSDX 165
May temperature at
inlet [°C]
CSDX 140 CSDX 165
May temperature on
inlet [°C]
CSDX 140 CSDX 165
Material CuNi10Fe CuNi10Fe

(inner pipes)
operating pressure
[bar]
May temperature at
course [°C]
Max volume- 11 11
flow [m3 /h]

Unsuitable coolants Salty water
pending funds The use of aqueous solutions is only permitted by agreement
Tab. 41 Specification: heat exchanger (option K9)

2 Specifications
2.16 Heat recovery system
2.15.2.2 Cooling water quality
Properties/contained substances closed system open system

cooling cooling
pH value Total 6,0 – 9,0 6,5 – 9,0
hardness [°dH] 0 – 20 0 – 20
Carbonate hardness [°dH] Chlorides <20 <4
(Cl) [mg/l] <500 <250
Dissolved iron (Fe) [mg/l] Sulphates <0,5 <0,2
(SO4 ) [mg/l] <300 <300
HCO3 /SO4 ratio >1 >1
Conductivity [µS/cm] 10 – 2500 10 – 2500
Ammonium (NH4 + ) [mg / l] <2 <1
Dissolved manganese (Mn) [mg/l] <0,1 <0,1
Glycol [%] 20 – 40 —
Solids <0,2 <0,2

(particle size) [mm]
Microbial number [CFU*/ml] 10 000 10 000
Particulate matter [ppm] <20 <20

(undissolved)
2.16 ÿÿÿÿÿ W1/W2/W3

Heat recovery system
2.16.1 Option W1
Preparation for an external heat recovery system
The characteristics and required volume flow of the heating medium depend on the
my heat exchanger.
Maximum allowable pressure drop in the oil circulation system: 0.6 bar
Maximum useful CSDX 140 CSDX 165

thermal power*
[kW] 69 80
[MJ / h] 247 286
[kcal / h] 58960 68390

*
at a control valve opening temperature of 80 °C
Tab. 43 Heat output (option W1)

2 Specifications
2.16 Heat recovery system
2.16.2 ÿÿÿÿÿ W2/W3

Internal heat recovery system
As a rule, water is used as the heating medium. To avoid damage
heat exchanger, it must comply with the quality indicated below.
ÿ For the use of an alternative heating medium, please contact your authorized
KAESER bathroom service.
The primary circuit of the heat exchanger is connected to the circulation system of the cooling
machine oils. The data given refer to the secondary circuit of the heat exchanger.
Properties/contained substances Meaning
pH value Total 7,5–9,0
hardness [°dH] 0–20
Carbonate hardness [°dH] <20
Chlorides (Cl) [mg/l] <100
Dissolved iron (Fe) [mg/l] Sulphates <0,5
(SO4 ) [mg/l] <300
HCO3 /SO4 ratio >1
Conductivity [µS/cm] 10–800
Ammonium (NH4 + ) [mg / l] <1
Dissolved manganese (Mn) [mg/l] <0,1
Glycol [%] 20–40
Solids (particle size) [mm] <0,1
Microbial number [CFU*/ml] 10 000
Particulate matter [ppm] <20

(undissolved)
CSDX 140 CSDX 165
Material 1.4401 1.4401
Solder Copper (Cu) Copper (Cu)

operating pressure
[bar]
(coolant)

May temperature at
course [°C]
Max volume- 23 23
flow [m3 /h]

2 Specifications
2.17 Refrigeration dryer
CSDX 140 CSDX 165
Unsuitable heat Salty water

sitters
The use of aqueous solutions is only permitted by agreement
Tab. 45 Specification: Heat exchanger (options W2/W3)
Thermal power
Maximum useful CSDX 140 CSDX 165

thermal power*
[kW] 69 80
[MJ / h] 247 286
[kcal / h] 58960 68390

*
at a control valve opening temperature of 80 °C
Tab. 46 Heat output (options W2/W3)
Option W2 Volume flow when heated from 45 °C to 70 °C (corresponds to ÿT=25K)
CSDX 140 CSDX 165
Tab. 47 Volume flow/pressure loss (option W2)
Option W3 Volume flow when heated from 15 °C to 70 °C (corresponds to ÿT=55K)
CSDX 140 CSDX 165
Tab. 48 Volume flow/pressure loss (option W3)
2.17 Refrigeration dryer

ÿneurosystem
ABT 165
Pressure loss [bar] 0,1

(reduced to 7 bars
surplus worker
pressure)
Maximum allowable 16
my excess work
what pressure [bar]
Tab. 49 Refrigeration dryer: Pneumatic system

2 Technical data 2.17 Refrigeration
dryer
Refrigerant circulation system
The refrigeration dryer is filled with a refrigerant that is characterized as a fluorinated greenhouse gas according
to the Kyoto Protocol.
ABT 165
Refrigerant R134a
Global Warming Potential 1300

(GWP)
Max quantity* [kg] Max.
pressure in bar (High
pressure side) 21
Max. pressure in bar 16

(low pressure side) Pressure
sensor: Switch-off pressure
[bar] 21
*
Record in the table the quantity of refrigerant charged indicated on the rating plate of the refrigeration dryer.
Tab. 50 Refrigeration dryer: Refrigerant circulation system

3.1 Basic information

The machine is manufactured in accordance with the state of the art and recognized safety regulations. However,
when using it, dangerous situations may arise:
ÿ danger to the health and life of the user or third parties,
ÿ causing damage to the machine and other valuable property.
Non-observance of the warnings and safety instructions can result in life-threatening injuries!
ÿ Only use the machine for its intended purpose and in a technically perfect condition,
awareness of possible dangers and strict adherence to the safety regulations described in the operating
instructions!
ÿ Violations that may affect safety must be immediately
eliminated!
3.2 Intended use

The machine is designed and intended exclusively for the production of compressed air in industrial areas. Any
other use is considered improper use. The manufacturer accepts no liability for material damage resulting from this.
The user alone bears the risk for this. ÿ Observe the instructions in these operating instructions. ÿ The machine may
only be operated within its capacity and in accordance with
permissible environmental conditions.

ÿ Do not use compressed breathing air without proper training. ÿ Do not use compressed air without
appropriate training for process applications.
processes where compressed air may come into contact with food.
3.3 Misuse
Improper use can result in property damage and/or (serious) injury.
ÿ Use the machine only for its intended purpose. ÿ Compressed

air must not be directed towards people or animals.
ÿ Use heated cooling air for heating if there is no risk
for human and animal health. If necessary, prepare cooling air by suitable measures.
ÿ Prevent suction of poisonous, acidic, flammable or explosive

gases or vapors.
ÿ Do not operate the machine in areas where special requirements regarding explosion protection must be observed.

3.4 User responsibility
3.4 User responsibility
3.4.1 Compliance with legal regulations and generally recognized rules

For example, national laws based on European directives and/or national laws, safety and
accident prevention regulations.
ÿ When installing, operating and maintaining the machine, observe the relevant
statutory regulations and generally recognized technical rules.
3.4.2 Determination of personnel

Suitable personnel are specialists who, on the basis of their professional training, erudition and
experience, as well as knowledge of the relevant regulations, can evaluate the work assigned to
them and recognize the possibility of dangerous situations.
Authorized service personnel must have the following qualifications: ÿ Be of legal age. ÿ Not only
studied the parts in the operating instructions regarding safety instructions,
dangers and maintenance, but also undertakes to comply with them.

ÿ Has the necessary knowledge and approval to facilitate reliable service
electrical and pneumatic devices.
ÿ Additional qualifications for machines with a refrigeration dryer: ÿ have
the necessary knowledge and approval to enable the reliable operation of refrigeration
equipment.
Authorized installation and maintenance personnel must have the following qualifications: ÿ Be of
legal age. ÿ Has not only studied the parts in the operating instructions regarding the safety,
installation and maintenance instructions, but also undertakes to observe them
ÿ Familiar with the concept and safety regulations for electrical and pneumatic
motehniki.
ÿ Can be aware of potential dangers in the operation of electrical and pneumatic technology and by
its actions prevent injury to persons and damage to property.
ÿ Has the necessary knowledge and approval to enable reliable

installation and maintenance of this machine.
ÿ Additional qualifications for machines with refrigeration dryer:
ÿ Familiar with the concept and safety regulations of refrigeration
that.
ÿ Can be aware of the potential for hazards in the operation of refrigeration technology and
can prevent injury to persons and damage to property by their actions.
ÿ Ensure that personnel responsible for maintenance, installation and installation

preventive, had the necessary qualifications and permission to perform the relevant work.

3.5 Hazards
3.4.3 Compliance with the terms of the technical examination and the rules for the
prevention of accidents
The timing of the technical inspection of the machine is set according to local regulations.
fork.
Application examples in Germany
ÿ Compliance with the test intervals according to BGR 500 Section 2.11 (Professional
accident insurance company): the company is responsible for
carrying out a functional test of the compressor safety devices, if necessary, but at least once
a year.
ÿ Compliance with the oil change interval according to BGR 500 Section 2.11:
the company is charged, if necessary, to make (and document) oil change in the compressor,
but at least once a year. Deviations are allowed if the analysis of the oil determines its further
suitability.
ÿ Compliance with the maximum terms of technical examination in accordance with
rules for safe operation according to §15:
Check Verification period Body conducting the check

Control of installation Before commissioning Accredited supervision service
and equipment
Internal check Every 5 years after installation Accredited Surveillance Service
tazha or last check
Check for pro- Every 10 years after the installation by an Accredited Surveillance Service
integrity or the last audit
Tab. 51 Terms of technical examination in accordance with the rules of safe operation
3.5 Hazards
Fundamentals
Here you will find information about the various types of dangers that may arise when operating
the machine.
The fundamental safety instructions in these operating instructions can be found at the beginning
of the relevant chapter in the "Safety" section.
Warning notices are immediately before the dangerous action.
3.5.1 Safe handling of hazards
Here you will find information about the various types of dangers that may arise when operating
the machine.
Electricity
Touching live parts can result in electric shock, burns, or death.

3.5 Hazards
ÿ Work on electrical equipment may only be carried out by authorized qualified electricians who have received professional
education or by personnel who have been instructed under the direction and supervision of an authorized qualified
electrician in accordance with electrical regulations.
ÿ Before each commissioning of the machine, the user must prepare and test the protection against dangerous voltage
with direct or indirect contact.
ÿ Before carrying out work on the electrical system: completely disconnect the residual
current circuit breaker from the mains, take measures against unintentional switching on, check the absence of
voltage.
ÿ Turn off additional external power supplies.
These include, for example, connections with potential-free contacts or electrical heating elements of the machine.
ÿ Use fuses suitable for the power of the machine. ÿ Regularly check that the electrical
connections are tight and in good condition.
pressure forces
Compressed air has energy. If it is released, life-threatening situations may occur. The following instructions apply to all
work on pressure equipment. ÿ By closing or switching off the compressed air network, it is safe to prevent the ingress of
compressed
th air from the pneumatic network to the machine.
ÿ Ensure that all components and vessels under pressure are free of pressure. ÿ Do not carry out welding, heat treatment or
mechanical modifications on pressurized equipment (eg pipes, tanks), as this may affect their strength. As a result, it is not
possible to ensure the safety of the machine.
Compressed air quality
The quality of the compressed air must be suitable for the specific application, without danger to health and life.
ÿ When using this machine's compressed air as breathing air

or in food production, use suitable compressed air systems.
ÿ Use a cooling oil suitable for use in the food industry.

areas where compressed air may come into contact with food.
elastic forces
When compressed, the springs store energy. If it is released, life-threatening situations may occur. The minimum pressure
check valve, safety valve and inlet valve are under spring force. ÿ Do not open or dismantle the valves.
Rotating elements
Touching the fan impeller, clutch and belt drive while the machine is running can cause serious injury.
ÿ Do not open the housing when the machine is switched on.

3.5 Hazards
ÿ Completely de-energize the residual current circuit breaker from the mains, take measures against
unintentional switching on, check the absence of voltage.
ÿ Work in tight-fitting clothing, if necessary, wear a hairnet. ÿ Before switching on, properly
install covers and protective grilles.
Temperature
When compressed, the temperature rises. Touching hot parts can cause injury.
ÿ Avoid touching hot parts. These include, for example,

the compressor block, oil and air lines, radiators, oil separator, motors and heating elements
of the machine.
ÿ Wear protective clothing. ÿ When
carrying out welding work on or near the machine, appropriate measures must be taken to prevent
ignition of machine components or oil vapors due to sparks or high temperatures.
Noise
The housing reduces the noise produced by the machine to a minimum. This is only possible with
the housing closed.
ÿ Operate the machine only with soundproofing elements. ÿ If necessary, wear ear protection.
Especially when air is vented through the safety valve, a lot of noise is generated.
Operating materials
The consumables used can lead to adverse health effects. Therefore, additional measures must be
taken to prevent the risk of injury.
ÿ Fire, open flames and smoking are strictly prohibited. ÿ Observe

the regulations for the safe handling of oils, lubricants and chemicals.
mimic substances.
ÿ Avoid contact with skin and eyes. ÿ Do not breathe
oil mist or vapours. ÿ Do not drink or eat when
handling coolants and lubricants. ÿ Keep appropriate fire fighting equipment ready. ÿ Only use
consumables approved by the company
KAESER.
Unsuitable spare parts
Unsuitable spare parts have a negative impact on the safety of the machine. ÿ
Use only spare parts approved by the manufacturer for use in
this machine.
ÿ Only use original spare parts for pressurized equipment.
KAESER parts.

3.5 Hazards
Alterations or modifications to the machine
Alterations or alterations to the machine or control unit may lead to unforeseeable consequences.
ÿ Do not modify or modify the machine. ÿ Technical

modifications and retrofits to the machine, control unit or software are only possible after obtaining
the written permission of the manufacturer.
Extension or modification of the compressor station
Only a properly sized safety valve reliably prevents an inadmissible increase in pressure.
Modification or expansion of the compressor station can lead to a deterioration in its safety. ÿ When
expanding or changing the compressor station:
Before installing a new machine, check the capacity of the safety valves on the air tanks and air
ducts.
ÿ If the flow rate is too low: Install a safety valve with
a suitable flow rate.
3.5.2 Safe use of the machine

Here you will find information about the rules of conduct that ensure the safe handling of the
machine in the individual stages of its use.
Personal protective equipment
When working with the machine, you may be exposed to danger leading to injuries with serious
consequences for health.
ÿ Wear protective clothing.
Examples of protective
clothing: ÿ Safety work clothes ÿ
Safety gloves ÿ Safety boots ÿ
Safety goggles ÿ Earmuffs
Transport
The weight and dimensions of the machine require safety precautions during transport to avoid
accidents. ÿ Use suitable lifting gear in accordance with local safety regulations.
ÿ Transport only by specially trained personnel authorized to

safe transportation of goods.
ÿ Attach lifting equipment only to the designated lashing points. ÿ Pay attention to the center
of gravity to avoid tipping over. ÿ Ensure that no one is in the danger area. ÿ Do not use the
machine as a step.

3.5 Hazards
Installation
ÿ Use cables that are designed and approved for the given operating conditions.
tation and expected load.
ÿ Install or remove pressure pipes only if there is no pressure

niya.
ÿ Use pressure lines that are designed for the maximum operating
medium pressure.
ÿ Pipe connections must not be subjected to self-weight forces. ÿ The machine must not be subjected to external
forces, while the acting forces must

zhny to be leveled with stops.
Installation location
In order to avoid accidents and malfunctions, a suitable place is needed to install

machine tanks.
ÿ Install the machine in a suitable machine room for this purpose. ÿ Provide the necessary lighting for
unhindered control of the displayed
information and safe work.
ÿ Make sure that the machine is easily accessible so that you can safely and unrestrictedly
personal work.
ÿ When installed outdoors, the machine must be protected from frost, direct
sunshine, dust and rain.
ÿ Do not operate in areas where special requirements must be observed

regarding explosion protection. For
example, the safety requirements for equipment operating in explosive atmospheres (zones) according to 94/9/EC
(ATEX Directive). ÿ Provide adequate ventilation. ÿ Install the machine without disturbing the working conditions in its
environment. ÿ Comply with the permitted ambient temperature and air humidity. ÿ The intake air must be clean and free
from harmful contaminants.
Examples of harmful impurities: explosive or chemically unstable gases and vapours, acids or alkali-forming substances
such as ammonia, chlorine or hydrogen sulfide.
ÿ Install the machine away from the hot air outlet area of other machines. ÿ Keep appropriate fire fighting
equipment ready.
Commissioning, operation and maintenance
During commissioning, operation or maintenance, you may be exposed to danger due to electrical voltage, pressure and
temperature. Careless actions can lead to injuries with serious consequences for health.
ÿ Work must only be carried out by authorized technical personnel. ÿ Wear tight-fitting, flame-retardant clothing.
If necessary
wear appropriate protective clothing.
ÿ Check that there is no voltage on the potential-free contacts. ÿ By closing or switching off the
compressed air network, it is safe to prevent the ingress of compressed


3.5 Hazards
ÿ Ensure and check the absence of pressure in all components and containers located
under pressure.
ÿ Allow the machine to

cool down. ÿ Do not open the housing when the
machine is switched on. ÿ Do not open or dismantle the
valves. ÿ Use only KAESER spare parts for use with this machine. ÿ Check regularly:
for visible damage, safety devices,

EMERGENCY STOP devices, items
to be checked.
ÿ When carrying out maintenance and repair work, observe the strictest cleanliness.
Cover components and open openings with a clean cloth with paper or foil to prevent dirt from
entering.
ÿ Do not leave tools, loose parts or cleaning cloths on or inside the machine.
material.
ÿ Dismantled elements can be dangerous: do not dismantle or crush
the dismantled elements.
Decommissioning/Storage/Disposal
Unsafe handling of used consumables and spare parts can endanger the environment. ÿ Dispose
of operating fluids and dispose of in an environmentally friendly manner.
vanities.
These include, for example, cooling oil and cooling water.
ÿ Disposal of refrigerant (if any) is carried out by specialized companies
we.
ÿ Dispose of the machine in accordance with environmental regulations.
3.5.3 Organizational arrangements
ÿ Identify staff and clearly allocate responsibilities. ÿ Adjust the

procedure for reporting faults and damage to the machine
rails.
ÿ Give instructions on measures to alert and eliminate the fire.
3.5.4 Dangerous areas
The table contains information on the size of possible danger zones for personnel. Access to
these areas is restricted to authorized personnel.
Work in progress Danger zone Authorized Personnel

Transportation 3 m around the car. Service personnel to prepare for transport.
During transport: none of the staff.
Under a raised car. None of the staff!

3.6 Safety devices
Work in progress Danger zone Authorized Personnel

Installation Inside the car. 1 Service personnel.
m around the machine and
its power cables. 1 m around
Exploitation the car. Service staff.
Maintenance Inside the car. Service personnel.
1 m around the car.
Tab. 52 Danger zones
3.6 Safety devices

Various safety devices ensure safe handling of the machine.
ÿ Do not modify, bypass or disable safety devices! ÿ Regularly check the function of the safety
devices. ÿ Do not remove or render illegible signs and symbols! ÿ Ensure that signs and
symbols are always recognizable!
Additional For more information on safety devices, see section 4, subsection 4.6.
Information
3.7 Safety signs
The figure shows the location of the safety signs on the machine. The applied safety signs and
their meaning are in the table.
Rice. 2 Location of safety signs

3.7 Safety signs
Position Symbol Meaning

1
Danger to life due to electric shock! ÿ Before carrying out any work on the electrical
niem:
completely disconnect the power supply, take measures against unintentional switching on
and check the absence of voltage.
2 Hot surface! Getting burned
when touching hot elements. ÿ Do not touch the hot surface. ÿ Work in long-
sleeved clothing (no clothing made of
synthetic materials, e.g. polyester) and protective gloves

chat rooms.
3 Severe injuries (especially to the hands) or detachment of limbs due to contact with rotating parts!
ÿ The machine may only be operated with closed safety
grilles, service doors and trim parts.
ÿ Before opening the machine, completely switch off the power supply and take measures
against unintentional switching on.
4 Risk of injury due to automatic start of the machine!
ÿ Before opening the machine, completely switch off the power supply and take measures
against unintentional switching on.
5 Danger to life when disassembling the valve (spring tension/pressure)! ÿ Do not open or dismantle
the valve. ÿ In the event of a malfunction, contact an authorized service center.
6 Severe injuries, especially when foreign bodies get into the eyes! ÿ Keep foreign objects
out of the ventilation

lattice.
ÿ No work may be carried out on the top of the machine,

if it is enabled.
8 Bearing failure due to lubrication at standstill! ÿ Lubricate the bearings only when the engine is
running. ÿ Only use ESSO UNIREX N3 for lubrication. ÿ Observe the maintenance intervals and
the amount of grease
lubricants.
9 Risk of falling or damage to the machine due to loads! ÿ Do not sit or walk on
covers. ÿ Do not place or store any objects on the covers.
Tab. 53 Safety signs

3.8 In an emergency
3.8 In an emergency
3.8.1 Correct actions in case of fire
Necessary measures
Calm and prudent action in a fire can save lives. ÿ Stay calm. ÿ Report a fire. ÿ If
possible, turn off the heat-power-water supply: residual current circuit breaker (de-
energize) cold water (if available) heat recovery system (if available)
ÿ Provide safety or alert personnel. ÿ Evacuate the helpless. ÿ Close the doors.
ÿ Appropriately trained: start extinguishing.
Fire-fighting equipment
ÿ Use suitable extinguishing media:

foam
carbon dioxide
sand or earth
ÿ Avoid using unsuitable extinguishing media:

strong jet of water
3.8.2 Treating injuries with cooling oil

In case of eye contact:
Cooling oil can cause irritation. ÿ Rinse eyes immediately

under running water for several minutes. ÿ Seek medical attention if irritation persists.
In case of skin contact:
Prolonged skin contact may cause irritation. ÿ Rinse thoroughly

with water, skin cleanser and soap. ÿ Remove contaminated clothing and use it only
after dry cleaning.
In case of poisoning:
Oil mist makes breathing difficult. ÿ Clear

airways of oil mist. ÿ Seek medical attention if you
experience difficulty breathing.
Swallowing:
ÿ Rinse mouth immediately with water.

3.9 Warranty
ÿ Do not try to induce vomiting. ÿ

Consult a doctor.
3.8.3 Help in the event of a refrigerant injury or poisoning

In case of eye contact:
possible eye irritation, tearing, redness, swelling of the eyelids. There is a risk of chemical
burns (frostbite). ÿ Open your eyelids wide to let the product evaporate. ÿ Rinse eyes
under running water for several minutes, eyelids should be
open.
ÿ In case of continuous pain in the eyes, consult an eye doctor.
In case of skin contact:
at first, a feeling of cold may appear, then redness of the skin. There is a risk of frostbite. ÿ
The agent must have evaporated. ÿ Rinse with warm water. ÿ In case of continuous pain or
redness on the skin, consult a doctor.
In case of poisoning:
at high concentrations, there is a risk of heart rhythm disturbance (arrhythmia). At high concentrations,
there is a risk of respiratory arrest due to lack of oxygen. ÿ Remove the victim from the contaminated area. ÿ If
necessary: connect a ventilator or supply
heard oxygen.
ÿ In case of shortness of breath (suffocation) or neurotic complaints, consult a doctor.
3.9 Warranty
These operating instructions do not specifically deal with any warranty. The KAESER General Terms and Conditions
of Business apply to the warranty. A prerequisite for the fulfillment of warranty obligations on our part is the use of
the machine for its intended purpose, taking into account the specific operating conditions. Due to the many possible
applications of the machine, the user must check whether the machine can be used in each particular case.
In addition, we do not accept warranty obligations in cases arising from ÿ the use of unsuitable parts and
operating materials,
ÿ unauthorized design changes,
ÿ poor maintenance,
ÿ poor-quality repairs.

3.10 Environmental protection
Proper maintenance and repair does not include the use of original spare parts and consumables.
ÿ Consult KAESER for specific operating conditions.
3.10 Environmental protection

Incorrect use of the machine can endanger the environment.
ÿ Do not allow oil to enter the environment and drains! ÿ Temporarily store
and dispose of all consumables and replacement parts in accordance with environmental
regulations.
ÿ Observe the relevant national regulations.
This applies in particular to elements contaminated with cooling oil.

4 Structure and principle of operation
4.1 Housing

4.1 Hull
Rice. 3 Housing image

1 Control cabinet door 2 Latch 3 Maintenance door 4 Panel part (panel)
When closed, the case performs various functions:

ÿ sound insulation
ÿ touch protection
ÿ directs the flow of cooling air
The body must not be used for the following: ÿ Walking, standing up or
sitting on a surface
ÿ warehousing or storage of various items
Safe and reliable operation is only guaranteed with the housing closed. There are opening doors and
removable parts of the skin (insertion panels). To open, the latches must be turned using the supplied key.
4.2 How the machine works

The principle of operation is described on the example of an air-cooled machine.

4 Design and function 4.2 Machine
function
Rice. 4 Machine picture

1 Inlet valve 2 Minimum 8 Air filter 9 Oil and air
pressure check valve cooler 10 Refrigeration dryer cabinet 11
nia Cyclone separator 12 Condensate drain
3 Compressor motor 4 Oil 13 Fan motor (variable speed)
filter 5 Compressor block 6
Switch cabinet 7 Oil separator
Air from the environment is sucked through the air filter 8 and cleaned in it. The air is then
compressed in the compressor unit 5 . The compressor unit is driven by an electric motor 3 .
The fan for cooling the machine is driven by a variable speed motor 13 . Refrigerant oil is injected
into the compressor block. It serves to lubricate moving parts and seal between the rotors and
between the housing and the rotors. Direct cooling in the compression chamber ensures a low
final compression temperature.
In the oil separator tank 7 , the cooling oil is separated from the compressed air and cooled in
the oil cooler 9 . It passes through the oil filter 4 and returns to the point of injection. The pressure
in the machine maintains the circulation system. No need for a separate pump. The control valve
(oil temperature controller) regulates and optimizes the temperature of the cooling oil.
The compressed air passes through the minimum pressure check valve 2 and enters the air
cooler 9 . To ensure constant circulation of the cooling oil in the machine, the minimum pressure
check valve maintains the required minimum pressure in the system.
In the air cooler, the compressed air is cooled down to a temperature only approx. 5 K – 10 K
above the ambient temperature. Most of the moisture contained in the compressed air is removed
and removed via the cyclone separator 11 and the condensate drain 12 .

4 Design and function 4.3 Parameters
4.2.1 Refrigeration dryer
Rice. 5 Refrigeration dryer

10 Refrigeration dryer
12 Condensate drain
A refrigeration dryer connected in series makes it possible to remove some of the condensed
moisture from the compressed air. The condensate is drained through the condensate drain.
4.2.2 Potential-free contacts

Potential-free contacts are available for message transmission.
Information about the status, load capacity and type of message can be found in the connection
diagram.
If the potential-free contacts are connected to an external voltage source, they can be
energized when the residual current circuit breaker is switched off.
network.
4.3 Options
Here you will find a description of the possible options for your machine.
4.3.1 Option H1
Screw-on machine feet
These screw-on feet ensure that the machine is securely fastened to the floor.
Rice. 6 Screw-on machine support

4.3.2 Option K2 / K9
Water cooling
Water-cooled machines use stainless steel plate heat exchangers (option K2) or tube heat exchangers
(option K9).
Option K2
Rice. 7 Water cooling (option K2)

1 Oil cooler 2 Air cooler 3 Cyclone separator 4
Condensate drain
Option K9
Rice. 8 Water cooling (option K9)

1 Oil cooler 2 Air cooler 3 Cyclone separator 4
Condensate drain
4.3.3 Option K3
Cooling air filter mat
Filter mats are designed to purify the cooling air and effectively protect the surface of the radiator
from contamination.

Rice. 9 Filter mat for cooling air (option K3)

1 Cooling air filter mat
4.3.4 Option W1/W2/W3

Heat recovery system
The cooling oil circuit has two valves that regulate the oil temperature:
ÿ Control valve: machine oil temperature controller ÿ Thermal valve: heat

recovery system temperature controller
Temperature controllers regulate the temperature of the cooling oil within the optimum operating
temperature range for the machine. First, the thermal valve opens and excess heat is transferred to
the heat recovery system. If the amount of heat exceeds the capacity of the heat recovery system,
the control valve opens and heat flows through the oil cooler.
Prerequisite: Thermal
valve opening temperature = Regulating valve opening temperature
The amount of useful heat depends on the operating conditions of the machine.
Option W1 Preparation for an external heat recovery system
Connections are provided for connecting an external heat recovery system. When the
machine is delivered, the thermal valve is not in working order. When installing the heat
recovery system, the operating element must also be installed. If necessary, the working
element of the control valve must be replaced with another one with a higher opening temperature.
The opening temperature depends on the operating and ambient conditions. The opening
temperature [°C] is indicated on the operating element.
If the cooling oil temperature is too low, condensation may form and damage the machine.
ÿ To select the right components and ensure the perfect operation of the cooling and heat
recovery systems, contact your authorized KAESER service center.

Operating modes and types of regulation
ÿÿÿÿÿ W2/W3 Internal heat recovery system
A plate heat exchanger is used for heat recovery. In the heat exchanger, heat is transferred
from the (hot) cooling oil
site.
To ensure the perfect operation of cooling and heat recovery systems, temperature controllers are equipped with working
elements.
Rice. 10 Internal heat recovery system (option W2/W3)

1 plate heat exchanger
4.4 Operating modes and types of regulation

4.4.1 Operating modes of the machine
The machine operates in the following operating modes:

ÿ LOAD: Inlet valve
open. The compressor unit supplies compressed air to the pneumatic network. The compressor motor is running
at full load. ÿ IDLE:
The inlet valve is closed. The minimum pressure check valve closes the air line between the oil separator and the
compressed air system. The inlet valve is open. A small amount of air circulates through the bypass on the intake
valve, the compressor block and then through the vent line back to the intake valve. The compressor motor runs
without load and consumes little energy.
ÿ STOP: Inlet valve

closed. The minimum pressure check valve closes the air line between the oil separator and the compressed air
system. The inlet valve is open. Compressor motor stopped.
Option C1 ÿ PARTIAL LOAD:

Depending on the actual compressed air demand, the inlet valve is opened and closed smoothly by means of a control
valve (proportional controller). The compressor unit supplies compressed air to the pneumatic network. The load and
energy consumption of the compressor motor increase/decrease depending on the demand for compressed air. The
control valve is adjusted at the factory. Changes are only possible after consultation with KAESER Service.

Operating modes and types of regulation
4.4.2 Types of regulation

In order to keep the excess working pressure of the machine between the set on and off pressure, regardless of the amount
of compressed air consumed, the control unit switches the machine according to certain rules (type of regulation) between
operating modes. In addition, the most energy-saving mode of operation of the machine is ensured by the regulation. The no-
load phase (depending on the machine) between the LOAD and STOP modes of operation provides a gentle load mode for
the mechanisms.
There are the following types of regulation of the SIGMA CONTROL 2 control unit:
ÿ DUAL
ÿ FRAMEWORK
ÿ VARIOUS
ÿ DYNAMIC
Option C1 ÿ PART LOAD control
Energy-saving controls for various compressed air applications:
Application Recommended type of

regulation
Pneumatic station consisting of one machine or machines with the same VARIED
capacity As part of the pneumatic station, the machine covers the peak
VARIO
loads
As part of the pneumatic station, the machine covers medium loads DYNAMIC*
As part of the pneumatic station, the machine covers the basic DYNAMIC*
loads
*
In the event of strong pressure fluctuations or frequent motor starts (current peaks), it is necessary to switch from
DYNAMIC to VARIO.
Tab. 54 Energy saving types of regulation
Unless otherwise agreed with the manufacturer, the control unit SIGMA CONTROL 2 is factory set to
the VARIO control type.
DUAL
In the DUAL control mode, the machine switches between LOAD and IDLE to keep the pressure between the set minimum
and maximum pressure. When the maximum pressure is reached, the machine switches to IDLE. After expiration, the
machine switches to STOP.
idle time ,
idle time set at the factory according to the frequency of compressor motor starts faster (thus more often)
gatel. The shorter the selected idle time ,
compressor motor is loaded.

4.5 Types of refrigeration dryer control
PAINTING
Compared to the DUAL control type, the machine switches to QUADRO after
period of low compressed air consumption from LOAD to IDLE.
After a period of high compressed air consumption, the machine switches from
LOAD to IDLE and then to STOP.
With this type of regulation, the control unit needs two preset times: time
idle move i idle/stop time .
The shorter this time is selected, the faster (thus more often) the engine stops.
compressor body.
VARIED
The VARIO control type is based on the DUAL control type. Compared to the view
DUAL regulation, this type of regulation automatically increases (decreases) time
me idling with frequent (rare) switching machines.
DYNAMIC
In contrast to the type of control DUAL, in DYNAMIC the machine switches from LOAD to
STOP at low compressor motor temperature.
When the compressor motor temperature is high, it switches from LOAD to
IDLE and then to STOP.
The lower the temperature of the compressor motor, the faster (thus more often and for more
longer period) the compressor motor stops.
Option C1 PARTIAL LOAD control
The PARTIAL LOAD control is an addition to the named types of control.

vanity. It smoothly changes the performance within the control range of the machine.
Compressed air requirement Operating modes

rises PART LOAD
LOAD
decreases PART LOAD

IDLING
STOP
Tab. 55 Operating modes for control type PART LOAD
4.5 Types of refrigeration dryer control

There are the following types of regulation of the control unit:
ÿ CONTINUOUS OPERATION
ÿ CLOCK SENSOR
CONTINUOUS OPERATION
The refrigeration dryer is always on, also when the machine is in standby mode.

4 Design and function 4.6 Safety devices
CLOCK SENSOR
When the machine is in standby mode, the refrigeration dryer turns on and off with a timer. The
temperature in the cooling system is constantly maintained within the required range.
This type of regulation is set at the factory.
When and what type of regulation is the most rational?
Type of regulation Advantage Disadvantage

CONTINUOUS Constant dew point. High energy consumption when the
OPERATION machine is in
me readiness.
CLOCK SENSOR Low electricity consumption Momentary exceedance of the energy point when
the engine is in standby mode when the engine is restarted. for the
compressor.
Tab. 56 Types of refrigeration dryer control
4.6 Safety devices

The following safety devices are available which must not be modified:
ÿ EMERGENCY STOP device:

The EMERGENCY STOP device is used to immediately stop the machine. The engine stops.
Air is vented from the pneumatic system.
ÿ Safety valve:
The safety valve protects the pneumatic system against impermissible pressure buildup.
Adjustment and adjustment is done at the factory.
ÿ Pressure sensor (machines with refrigeration dryer):
The safety pressure sensor protects the refrigerant circuit against unacceptable pressure
buildup. It is not regulated. ÿ Housing and protective covers for moving parts and electrical
connections:
they protect against unintentional contact.

4.7 SIGMA CONTROL 2 control panel

Buttons
Rice. 11 Button image
Position Name Principle of operation

1 "OFF" Turn off the machine.
2 "ON" Turn on the machine.
3 «ESC» Return to a higher menu level.
Exit change mode without saving.
4 "ENTER" Enter the selected submenu.
Exit change mode with saving.
5 "WAY DOWN" Scroll down the menu.
Decreasing the value of the parameter.
6 "RIGHT" Move to the right.


7 "LEFT" Move to the left.
8 "UP" Scroll up the menu.
Increase the parameter value.
9 "Status and information" Operation indication:
Archive display.
10 "ACKNOWLEDGE" Confirmation (acknowledgement) of messages about
health and warnings.
If possible: deletion of error messages
archived news (reset).
11 "LOAD/IDLE" Switching between operating modes
LOAD and IDLE.
12 "Remote control" Turn on/off the remote control
leniya.
13 Timer Turn the timer on and off.
Tab. 57 Buttons
Indicators
Rice. 12 Overview of indicators
Position Description Principle of operation

14 Display panel Graphic display (8-line, 30-digit).
or display
15 Malfunction In the event of a fault, the red LED flashes.
After acknowledgment lights up continuously.
16 Connection The red LED lights up continuously when communicating.
cation failures (Ethernet, USS, COM modules).


17 Warning The yellow LED flashes when:
ÿ the need for maintenance,
ÿ warning message
After acknowledgment lights up continuously.

18 The green LED lights up continuously when the power is on.
Control box power nutrition.
19 LOAD The green LED lights up continuously if the machine is

works in LOAD mode.
20 IDLING The green LED lights up continuously if the machine is
operates in IDLE mode.
Flashes when manually switched using the button
"LOAD/IDLE".
21 The LED lights up when the machine is controlled from a remote
Remote control remote control.
22 Timer The LED lights up if the machine is controlled by a timer.
23 Machine ON The green LED lights up continuously when the machine
included.
Tab. 58 Indicators
RFID reader
"Radio Frequency Identification" (RFID for short) allows automatic identification of

vat objects.
If you bring the appropriate transponder close to the RFID reader, it will automatically
The communication between the transponder and SIGMA CONTROL 2 is carried out.
KAESER RFID ID card is a transponder. Together with the machine you
got 2 cards.
Application:
ÿ The user must register to operate the machine.
(There is no need to enter the password manually.)
Rice. 13 RFID reader

Position Name Operating principle

24 RFID The RFID reader is designed to read
signal sent by the RFID transponder.
Tab. 59 RFID reader
Additional Detailed information about RFID can be found in the user manual
information SIGMA CONTROL 2 .

5.1 Safety precautions

The conditions in which the machine is installed and operated have a decisive influence on safety.
Non-observance of the warnings can result in life-threatening injuries!
Compliance with safety regulations
Failure to follow the safety instructions can result in life-threatening injuries! ÿ Fire, open flames and
smoking are strictly prohibited. ÿ When carrying out welding work on or near the machine,
appropriate measures must be taken to prevent ignition of machine components or oil vapors due
to sparks or high temperatures.
ÿ Do not store flammable materials near the machine. ÿ

Machine of general industrial (non-explosion-proof) design:
Do not operate in areas where special requirements regarding explosion protection must be
observed. For example, the safety requirements for equipment operating in explosive
atmospheres (zones) according to 94/9/EC (ATEX Directive).
ÿ Provide the necessary lighting for unhindered control of the displayed

information and safe work.
ÿ Keep appropriate fire fighting equipment ready. ÿ Observe the required
ambient conditions.
The required operating conditions include, for example: ÿ

Compliance with the ambient temperature and air humidity ÿ
Maintaining the required air quality in the machine room:
ÿ clean and free from harmful impurities (e.g. dust, fibres, fine sand) ÿ free from
explosive or chemically unstable gases and vapors ÿ free from acid/alkali forming
substances, especially ammonia, chlorine or hydrogen sulfide
5.2 Conditions at the installation site

5.2.1 Determining the installation location and distances
The machine is designed to be installed in a suitable machine room for this purpose. Here you will
find information regarding ventilation and distances from walls.
The specified distances are recommended and provide unhindered access to all parts of the
machine.
ÿ If these distances cannot be observed, please consult KAESER.

5 Installation and operating conditions 5.2
Conditions at the installation site
Prerequisite The floor at the installation site must be horizontal, solid and load-bearing,
corresponding to the weight of the machine.
Rice. 14 Installation recommendations, dimensions [mm]

A Exhaust fan
B Exhaust duct
Z Ventilation opening
1. NOTE!
Too low ambient temperature! Condensate
freezing and deterioration of the lubricating properties of the oil due to increased viscosity
can cause damage to the machine during start-up. ÿ Before switching on, make sure that
the temperature of the machine is at least +3ÿ. ÿ Provide sufficient room heating or install a
heating system.
2. Provide accessibility to the machine and the necessary lighting to carry out various work safely
and without restrictions. 3. Make sure that the display of the control unit is not exposed to direct
sunlight (so as not to damage it) and that the indicators do not glow. 4. Ensure that the air intake
and exhaust openings are open. 5. When installed outdoors, the machine must be protected
from frost, direct
sunshine, dust and rain.
5.2.2 Ventilation of machinery space

Proper ventilation of the machine room ensures the following:
ÿ prevents underpressure in the machine room. ÿ removes the machine's
radiant heat, thus ensuring the necessary operating
tional conditions.
ÿ If it is not possible to provide the necessary ventilation in the machine room

KAESER specialists.
1. Ensure that the amount of supply air is at least equal to the amount of air taken in by the
machine and the exhaust fan in the machine room.

5 Installation and operating conditions 5.3 Operation
of the machine connected to the pneumatic network
2. Ensure that the supply air opening is always open when the machine is running.
and an exhaust fan.
3. Do not block the ventilation openings for supply and exhaust for unobstructed
th air movement through the engine room.
4. Ensure the supply of clean air for the correct functioning of the machine.
5.2.3 Design of the exhaust ventilation duct

On the air inlet and outlet side, the machine can overcome the air resistance due only to the design. Any additional
resistance impedes airflow and affects the cooling of the machine.
ÿ Determine only after consultation with KAESER Service:

ÿ Calculation of the outflow duct ÿ Transition between
the machine and the outflow duct
ÿ channel length
ÿ number of knees
ÿ design of dampers or blinds
Option K1:
Only use dampers or louvre dampers that are controlled by a motor
my tongue
Dampers or louvres that are opened by the flow of air do not open sufficiently at a low speed of the cooling air fan.
Additional Information Information on the design of the outflow ventilation duct can be found in section 13.3.
5.3 Operation of the machine connected to the pneumatic network
When the machine is connected to a pneumatic network, the excess operating pressure of the pneumatic network must not
exceed 16 bar (China: 15.9 bar). When filling an empty pneumatic network with compressed air, a very high flow velocity
usually occurs inside compressed air preparation devices. Under such conditions, they cannot function perfectly. The
compressed air quality is deteriorating. To ensure the required quality of compressed air, we recommend installing a
pressure maintenance system to control the filling of an empty pneumatic network. ÿ Consult KAESER.

6 Installation
6 Installation
Here you will find safety instructions for installation work. Warning notices are immediately before the dangerous action.
Failure to follow the safety instructions can result in life-threatening injuries! ÿ Observe the instructions in section 3 "Safety
and liability
ness".
ÿ Installation work must only be carried out by authorized service personnel.

scrap!
ÿ Ensure that no personnel is working on the machine. ÿ Make sure that all
maintenance doors and trim parts are closed.
Carrying out work on live parts under voltage
ÿ Work on electrical equipment may only be carried out by an authorized

qualified electrician.
ÿ Check that there is no voltage on the potential-free contacts.
Carrying out work related to the compression system
Compressed air has energy. If it is released, life-threatening situations may occur. The following safety instructions apply
to all work on pressurized equipment.
ÿ By closing or switching off the compressed air network, it is safe to prevent the ingress of compressed
ÿ Ensure that all components and vessels under pressure are free of pressure. ÿ Using a manual
pressure gauge, check if there is excess pressure on the couplings of the system
compression should be 0 bar.
ÿ Do not open or dismantle the valves.
Carrying out work related to the drive system
Touching live parts can result in electric shock, burns, or death. Touching the fan impeller, clutch and belt drive while the
machine is running can cause serious injury.

6 Installation
6.2 Reporting damage in transit
Additional Information regarding authorized personnel can be found in section 3.4.2. Information
Information about dangers and their prevention can be found in section 3.5.
6.2 Reporting damage in transit

1. Check the machine for visual and hidden damage during transport. 2. If damage is
found, immediately inform the shipping company.
firm and manufacturer in writing.
6.3 Connecting the machine to the compressed air network

Condensation in the compressed air network can damage the pipes:
ÿ Use anti-corrosion pipes, ÿ Use fluorinated

elastomer seals, ÿ Pay attention to the electrochemical stress
range of metals, ÿ Check with KAESER on the use of suitable piping.
Mandatory condition Lack of pressure in the pneumatic network.
Rice. 15 Air line

1 Axial expansion joint or flexible hose 2
Shut-off valve
ÿ No external forces must be transmitted to the machine, and the forces must be leveled out
by stops.
1. WARNING! Risk of
serious injury when disassembling or removing pressurized components! ÿ Ensure that all
pressurized components and containers are free of pressure.
laziness.

6 Installation
6.4 Electrical connection
2. Install a shut-off valve on the connecting pipe. 3. Connect an axial compensator or

flexible hose.
Additional Information The dimensions and position of the compressed air connection can be found on the outline drawing in section 13.3.
6.4 Electrical connection

Prerequisite De-energize the electrical network,
take measures against unintentional switching on, check the absence of
voltage.
1. Electrical connection must only be carried out by authorized service personnel or authorized qualified electricians. 2.
Implement the necessary protective measures in accordance with the relevant regulations
(eg IEC 364 or DIN VDE 0100) and national accident prevention regulations (for Germany BGV A3). In addition, the
regulations of the local power companies must be observed. 3. Check the allowed tripping time of the overcurrent
protection device in case of
when a malfunction occurs.
4. Calculation of the section of power cables and fuses is made taking into account the corresponding
applicable local regulations.
5. The user must equip the machine with a closable residual current circuit breaker.
network.
This is, for example, a switch-disconnector with fuses connected upstream. When using a circuit breaker, pay attention
to the starting characteristics of the motor.
6. Check the connection of the control transformer according to the voltage

network.
If necessary, adjust the transformer connection according to the voltage
network.
7. DANGER!
Danger to life due to electric shock! ÿ Turn off the power supply completely, take measures
against unintentional
switch on and check the absence of voltage.
8. Connect to the power supply. 9. Make sure that the switch cabinet
complies with the degree of protection IP54.
Additional Information See the wiring diagram in section 13.4 for more information on the electrical connection.
6.4.1 Option T2
Refrigeration dryer: matching to mains voltage
The refrigeration dryer transformer has electrical connections for various mains voltages.

6 Installation
6.5 Connecting the condensate drain
1. Check the connection of the transformer according to the mains voltage. 2. If necessary,
adjust the transformer connection according to the voltage
network.
Additional The connection diagrams in section 13.4 provide additional information regarding the electrical
Information connection.
6.5 Connecting the condensate drain

A threaded connection is provided for connecting the drain hose to the condensate drain.
It is necessary to ensure unhindered drainage of condensate.
The figure shows a typical installation. The condensate

drain into the collection condensate line occurs from above. In this way, you can prevent condensate from
flowing back into the machine from the condensate collection line.
Rice. 16 Condensate drainage system, dimensions [mm]

1 Threaded connection 2
Collective condensate line
ÿ Connect the drain hose.
ÿ The condensate must be drained into a collector and then disposed of according to
environmental regulations.
Additional The dimensions and position of the connection for the condensate drain can be found on the outline
Information drawing in section 13.3.

6 Installation
6.6 Options
6.6 Options
6.6.1 Option H1
Machine attachment
ÿ Fasten the machine to the floor using suitable fasteners.
Additional The dimensions of the fixing holes can be found on the outline drawing in section 13.3.
Information
6.6.2 Option K2/K9

Connecting the cooling water system
ÿ To connect the supply and return pipelines, select water pipes of the appropriate material,
paying attention to the electrochemical voltage range of the metals.
ÿ The hydraulic loads on the radiator must be kept to a minimum. ÿ If water hammer
cannot be prevented, an equalization
vessel as pressure reducer.
ÿ Avoid supplying water that is too cold, as the pipes may fog up. If necessary, consult
KAESER for appropriate pipe insulation measures.
Temperature-controlled cooling water systems connected to several machines regulate the flow
of cooling water depending on the temperature difference between the supply and return water.
This may result in insufficient cooling water for one of the machines. As a result, malfunctions may
occur.
ÿ Consult KAESER to equip the cooling water system with the required control valves.
Rice. 17 Cooling water connection A Cooling water outlet 12

Connecting plug with plug B Cooling water inlet 17 Safety valve 10 Shut-off cock

6 Installation
6.6 Options
1. The user must provide for the installation of the following fittings:
ÿ dirt trap (mesh size selected according to particle size) ÿ shut-off valves 10 and
connection fittings 12 for maintenance and disposal
air.
ÿ safety valve 17 for protection against impermissible pressure increase. The set pressure and
flow capacity of the safety valve are determined depending on the design and installation.
In this case, it is necessary to take into account the technical characteristics of the radiator.
2. Install fittings on the cooling water pipes. 3. Open the shut-off valve at the cooling water
outlet A . 4. Slowly open shut-off valve at cooling water inlet B and gradually fill the radiator with
cooling water. 5. Remove air from the cooling water pipes.
Additional The flow direction, dimensions and position of the connection fitting can be found on the outline
6.6.3 Option W1/W2/W3

Heat recovery connection
ÿ For the connection of the inlet and outlet pipes, select pipes of suitable material, paying
attention to the electrochemical voltage range of the metals.
ÿ The hydraulic loads on the heat exchanger must be kept to a minimum. ÿ If water
hammer cannot be prevented, an equalization
vessel as pressure reducer.
ÿ If the temperature of the heating medium at the outlet is to be constant, it is necessary to
install the appropriate adjustment device.
ÿ Avoid supplying heating medium that is too cold, as the pipes may fog up. If necessary,
consult KAESER for appropriate pipe insulation measures.
WARNING Coolant oil

entering the heating medium! If a leak occurs, cooling
oil may enter the coolant. ÿ Do not use the heating medium as drinking water.
ÿ Install the heat recovery system according to the following instructions.

niami.
Additional The flow direction, dimensions and position of the connection fitting can be found on the outline
6.6.3.1 Option W1
External heat recovery connection
The use of an unsuitable heat exchanger or improper installation can lead to an interruption
in the circulation of the cooling oil inside the machine. As a result, damage to the machine
may occur.
ÿ Coordinate with KAESER the appropriate type of heat exchanger and have the installation
carried out by an authorized KAESER service.

6 Installation
6.6 Options
6.6.3.2 Option W2/W3

Connecting an internal heat recovery system
Connecting an internal heat recovery system
Rice. 18 Connecting the heat recovery system

A Exit 12 Connecting nipple with plug 17 Safety
B Inlet valve
10 Shut-off valve
1. The user must provide for the installation of the following fittings: ÿ Dirt trap
with holes no larger than 0.1 mm. ÿ shut-off valves 10 and connection
fittings 12 for maintenance and removal
air.
ÿ safety valve 17 for protection against impermissible pressure increase. The set pressure
and flow capacity of the safety valve are determined depending on the design and
installation. In this case, the technical characteristics of the heat exchanger must be
taken into account.
2. Install fittings on pipelines. 3. Open shut-off
valve 10 at outlet A . 4. Slowly open shut-off
valve 10 at inlet B and gradually fill the heat exchanger
nick coolant.
5. Remove air from pipelines.

7 Commissioning
7 Commissioning
Here you will find instructions for safe commissioning work.
Failure to follow the safety instructions can result in life-threatening injuries! ÿ Observe the
instructions in section 3 "Safety and liability
ness".
ÿ Commissioning work must only be carried out by an authorized
bathroom installation staff!
ÿ Ensure that no personnel is working on the machine. ÿ Make sure
that all maintenance doors and trim parts are closed.

Compressed air has energy. If it is released, life-threatening situations may occur. The following
safety instructions apply to all work on pressurized equipment.
Touching live parts can result in electric shock, burns, or death. Touching the fan impeller, clutch
and belt drive while the machine is running can cause serious injury.

7 Commissioning 7.2 Before
commissioning
Additional Information regarding authorized personnel can be found in section 3.4.2. Information
Information about dangers and their prevention can be found in section 3.5.
7.2 Before commissioning

Incorrect or improper commissioning can result in damage to the machine or personal injury.
ÿ Commissioning must only be carried out by authorized installation personnel.

maintenance and service trained on this machine.
Special measures before commissioning after long periods of storage/outages
Duration of Measures
storage / interruption
in work, more
3 months ÿ Fill cooling oil into the compressor block. ÿ Change the oil
12 months filter. ÿ Replace oil separator element. ÿ Change the cooling
oil. ÿ Have the motor bearings checked by an authorized
KAESER service bathroom.

36 months ÿ Checking the general technical condition by authorized
KAESER Service Center.
Tab. 60 Commissioning after extended storage/outage
7.3 Monitoring compliance with installation and operation requirements

ÿ Putting the machine into operation only after completing all the points of the check
list.
Need to check Cm. Performance

section
ÿ Are the operating personnel familiar with the technical –
security nicknames?
ÿ Have all installation requirements been met? 5
ÿ Has the user installed a lockable network residual current device? 6.4
ÿ Does the actual mains voltage match the data on the type plate? 2.1
ÿ Are the fuses and conductor cross-sections correctly dimensioned? 2.14

kov?

7 Commissioning 7.4
Installing the magnetic starter
Need to check Cm. Performance

section
ÿ Are the parameters of the magnetic motor starter correct? 7.4

compressor mains voltage?
ÿ Are the parameters of the motor protection switch correct? 7.5

fan mains voltage?
ÿ Option T2: Check transformer connection according to 6.4.1

network voltage.
–
ÿ Have all electrical connections been checked for tightness?
of?
ÿ Is a shut-off valve installed at the compressed air outlet? ÿ Is the connection to the 6.3
compressed air network made with a flexible 6.3

hose or axial compensator?
ÿ Is the condensate drain connected? 6.5
ÿ Is there enough cooling oil in the oil separator tank? 10.13

caster?
(oil gauge is outside the red zone)
ÿ Has sufficient cooling oil been filled into the compressor block? ÿ Is the machine secured 7.6
to the floor? (option H1)
6.6.1
ÿ Is there a cooling water supply? (option K2/K9) 6.6.2
–
ÿ Are all maintenance doors and parts closed?
cladding?
Tab. 61 Installation Requirements Checklist
7.4 Installing the magnetic starter

The setting values for the magnetic starter can be found in the connection diagram in section 13.4.
When starting in a star-delta configuration, the phase current passes through the magnetic starter. This phase current is 0.58
of the compressor motor current consumption. To prevent the magnetic starter from tripping due to voltage fluctuations,
temperature influences or structural tolerances, the set value must be greater than the rated phase current. ÿ Check the
magnetic starter settings.
If, despite correct installation, the magnetic starter switches off the machine: ÿ Contact an authorized KAESER
service center.
7.5 Adjusting the motor protection switch

The settings for the motor protection switch can be found in the connection diagram in section 13.4.

7 Commissioning 7.6 Filling
cooling oil into the compressor block
In direct starting, the phase current of the fan motor is routed through the motor circuit breaker.
To prevent tripping of the motor circuit breaker due to voltage fluctuations, temperature
influences or component tolerances, the set value must be greater than the rated motor
current.
ÿ Check the set value (trip) of the motor protection switch.
If, despite the correct setting, the motor protection switch switches off the machine:
ÿ Contact an authorized KAESER service center.
7.6 Filling cooling oil into the compressor unit

During the first commissioning, as well as commissioning after a long (more than 3 months)
shutdown, it is necessary to fill the cooling oil into the compressor block. To prevent the level from
rising, drain the required amount of oil from the oil separator. For more information on draining the
cooling oil from the oil separator, see section 10.16.
Material 2 liters of cooling oil from the oil separator
Prerequisite The mains residual current device is completely de-energized,

measures have been taken against unintentional switching on, the
absence of voltage has been checked.
Depressurize the machine, the pressure gauge on the oil separator should show 0 bar.
Rice. 19 Filler port on inlet valve 1 Plug 2 Inlet valve
1. Unscrew the filler plug on the inlet valve. 2. Pour cooling oil into
the compressor block and tighten the plug.

7 Commissioning 7.7
Switching PART LOAD control on and off
Rice. 20 Clutch
1 Compressor block 2 Clutch 3 Cover 4
Direction of rotation arrow
1. Unscrew cover 3 . 2. In
direction of rotation 4 , turn compressor block 1 by hand using
clutches 2 . 3. Replace
cover 3 .
7.7 Option C1
Switching PART LOAD control on and off
The PARTIAL LOAD control is switched on and off by means of a shut-off valve. With PART
LOAD control switched off, the machine in LOAD mode produces the maximum amount of
compressed air.
PARTIAL LOAD control Stopcock

included open
turned off closed
Tab. 62 PART LOAD control: shut-off valve positions


7 Commissioning 7.8 Switching on
the machine for the first time
Rice. 21 PART LOAD control: Stop valve positions 1 Control valve (proportional
controller) 2 Stop valve
ÿ Depending on the operating mode, open or close the shut-off valve.

The control valve is adjusted at the factory. Changes are only possible after consultation with
KAESER Service.
7.8 Switching on the machine for the first time
Prerequisite No personnel are working on the machine. All maintenance

doors are closed. All parts of the skin are installed and
fixed.
1. Open the shut-off valve of the pneumatic network.

2. Turn on the mains residual current device. After loading
the control unit, the green LED is continuously lit Food
control unit .
3. If necessary: change
the display language as described in section 7.10.
4. Press the "ON" button.
The compressor motor starts running, after a short time the machine switches to LOAD mode
and produces compressed air.
ÿ Observe the machine during the first hours of operation to check for malfunctions. ÿ After
50 hours of operation after initial commissioning, check the tightness of all electrical
connections.
If the machine stops because the compressor motor is turning in the wrong direction:
ÿ Completely de-energize the residual current circuit breaker from the mains, take
measures against unintentional switching on, check the absence of voltage.
ÿ Swap cables L1 and L2.

7 Commissioning
7.9 Setting the set network pressure
7.9 Setting the set network pressure

The set network pressure pA is set at the factory to the maximum possible value.
The parameters must be adapted to the individual operating conditions.
tion..
The set network pressure set in the machine must not exceed the maximum
operating overpressure of the connected pneumatic network.
The maximum allowable switching of the machine between LOAD and
IDLE is twice per minute.
To optimize the switching frequency:
ÿ increase the difference between the switch-on and switch-off pressures.
ÿ Connect a larger compressed air tank.
ÿ Set the desired network pressure in accordance with the instructions for use
SIGMA CONTROL 2 .
7.10 Changing the display language

On the control unit, text messages can be displayed in different languages.
Set the desired language to be shown on the display. Co-setting
stored even when the machine is turned off.
1. When the operating parameters are displayed on the screen, go to the main menu by pressing the button
ku "INPUT".
2. By pressing the "UP" or "DOWN" buttons, select the line containing the current language:
6. 1 b a r 8 0 ,
0ÿ
-------- German -------- Current language (active line)

ÿ 1 xxxxxxxxxx Submenu
3. By pressing the "ENTER" button, go to the installation mode.

The language display will flash.
4. Use the UP and DOWN buttons to select the desired language.
5. Press the ENTER button to confirm the change.
Result The information shown on the display will appear in the selected language.
Additional Detailed information can be found in the SIGMA CONTROL 2 user manual.
information

8 Operation
8.1 Switching on and off
8 Operation
8.1 Switching on and off
The machine must always be switched on with the "ON" button and switched off with the "OFF" button.
Installation of the residual current circuit breaker is carried out by the user.
Rice. 22 Switching on and off
1 LED 2 ON Machine ON (green) 11 LOAD/IDLE button

button 19 LED 20 LED LOAD
3 OFF button IDLING
8 LED (green) Control box power
8.1.1 Switching on
Prerequisite No personnel are working on the machine.

All maintenance doors and trim parts are closed.
1. Turn on the mains residual current device.

After loading the control unit, the green LED is continuously lit Food
control unit .
2. Press the "ON" button.

Green LED Machine ON glows continuously.
In the event of a power failure, the machine is not blocked against automatic
launches.
As soon as the power supply is restored, an automatic
start.
Result The compressor motor starts as soon as the network pressure falls below the set pressure.
set network pressure (switch-off pressure).
8.1.2 Shutdown
1. Press the LOAD/IDLE button.

Machine switches to IDLE and LED flashes IDLE MOVE .

8 Operation
8.2 Switching on and off in an emergency
2. After at least 20 s at IDLE: press the "OFF" button.

LED 3. Machine ON will go out.
Press the "LOAD/IDLE" button.
LED The IDLING will go out.
machine is in ready mode. You can turn it back on.

4. Completely de-energize the residual current device from the mains and take measures against
unintentional activation.
Result LED Control box power will go out. The machine is completely turned off and no
power is supplied.
8.2 Switching on and off in an emergency

The EMERGENCY OFF device is located under the control panel.
Rice. 23 Shutdown in emergency

9 EMERGENCY STOP device
Shutdown
ÿ Press the EMERGENCY STOP device.
Result After pressing the EMERGENCY OFF device remains blocked.

The pressure in the system is relieved and the machine is protected from automatic start.
Inclusion
Prerequisite Fault corrected
1. Unlock the EMERGENCY OFF device by turning it in the indicated

direction arrow.
2. Acknowledge the existing error message.
Result You can now turn on the machine again.
8.3 Switching on and off with remote control

Prerequisite Communication with the remote control.

8 Operation
8.4 Switching on and off with the timer
Rice. 24 Switching on and off from the remote control 1 "REMOTE"

button 2 LED
DIST
1. Affix a warning label indicating the remote control in a visible position on the machine:
Remote control: risk of injury due to unexpected start! ÿ Make sure that the residual current
circuit breaker
was off.
Tab. 63 Identification on the machine
2. Sign the launcher on the remote control:
Remote control: risk of injury due to unexpected start! ÿ Make sure that no one is working
on the machine and that it can be switched on safely.
Tab. 64 Designation on the remote control
3. Press the "DIST" button. Light-

emitting diodeDIST glows. Now you can control the machine from the remote
remote control.
8.4 Switching on and off with the timer

Prerequisite The timer has been programmed.

8 Operation
8.5 Operational messages
Rice. 25 Switching on and off with the timer

1 TIMER button 2 LED
TIMER
1. In a conspicuous place on the machine, affix a warning label with the designation
timer control:
Timed control: risk of injury due to unexpected start! ÿ Make sure that the residual
current circuit breaker
was off.
Tab. 65 Identification on the machine
2. Press the "TIMER" button. Light-

emitting diodeTIMER glows. The timer turns the machine on and off.
8.5 Operational messages

If necessary, the control unit automatically displays operating messages and informs you about the
technical status of the machine. Operational messages are designated by the letter "E".
Additional Detailed information can be found in the instructions for use of SIGMA CONTROL 2.
Information
8.6 Acknowledging fault and warning messages

yah
A message is displayed in the following way: ÿ message arrived:

LED flashes ÿ message will be acknowledged: LED lights up
permanently ÿ message left: LED does not light up

8 Operation
or
ÿ message arrived: LED flashes

ÿ message gone: LED flashes
ÿ message will be acknowledged: LED off
Rice. 26 Message acknowledgment

10 LED 11 LED Warning Fault (yellow)
12 "Success" (red)
button
Fault message
If a malfunction occurs, the machine will automatically turn off. Red LED
Malfunction blinking.
A corresponding message will appear on the display.
Prerequisite Fault corrected
ÿ Acknowledge the message with the "ACKSITE" button.

LED The Malfunction will go out.
machine is ready to start again.

If the machine has been switched off by the EMERGENCY STOP device:
ÿ Before acknowledging the error message, unlock the ABA-
STOP by turning the lock in the direction indicated by the arrow.
Additional A list of possible error messages can be found in the user manual.
information SIGMA CONTROL 2.
warning message
If maintenance is required or a fault warning is displayed,

correct, the yellow LED flashes. The Warning .
corresponding message will appear on the display.

8 Operation
Prerequisite The danger of a malfunction has been eliminated

Maintenance done
ÿ Acknowledge the message with the "ACKSITE" button.

Light-emitting diode Warning will go out.
Additional A list of possible warning messages can be found in the user manual.
information SIGMA CONTROL 2.


There are 3 types of errors: ÿ
Warning:
ÿ Warning messages ÿ Fault (with a P
message) ÿ Fault messages ÿ System messages
ÿ Diagnostic messages N
Y
D
ÿ Other faults (no message): see section 9.2.
The messages that are valid for your machine depend on the individual implementation.
machine.
1. Take action only in accordance with the instructions given in this manual.
instructions for use! 2.
Otherwise: have the fault
repaired by an authorized KAESER service center.
Additional Detailed information regarding the various messages can be found in the SIGMA CONTROL 2
Information user manual.
9.2 Other faults

Malfunction Possible reason Measures
Machine runs but does not Inlet valve not open Contact KAESER Service.
produce compressed air. or only partially
opens.
Air vent valve does not close. Contact KAESER Service.
Leakage in pneumatic system Check lines and connections for

stem. leaks and tighten loose
connections.
The demand for compressed Check pneumatic network for

air exceeds the production leaks.
machine performance.
Switch off all consumers.
The nozzle insert/hose for Remove the nozzle insert/

maintenance is located in the maintenance
on the reservoir
hose. coupling
layer separator.

9.2 Other faults
Malfunction Possible reason Measures
Oil is escaping from the air filter. The oil level in the oil recovery tank Drain the oil to the correct level.
is too high.
divider.
Inlet valve defective. Contact service

KAESER services.
Machine switches from LOAD to The buffer capacity of the receiver is Increase Buffer Capacity
IDLE more than twice per minute. too small. bone.
Restricted flow in pneumatic Increase the diameter of the compressed

net. air line.
Check filter elements.
Switching difference between pressure Check switch difference

too small cheniya.
switching on and off
cheniya.
Cooling oil in the machine- Nozzle insert/hose for Remove nozzle insert/maintenance is located in the service hose.
not. coupling on the oil separator tank.
Oil cooler leaking Contact KAESER Service.

tic.
Leaks at connections. Tighten screw connections

niya.
Replace gaskets.
Too much cooling oil consumption. Unsuitable coolant Use SIGMA FLUID coolant.
oil.
Rupture of a replaceable Replace replacement element

element of an oil separator. oil separator.
The oil level in the oil recovery tank Drain the oil to the correct level.
is too high.
divider.
The oil return line is dirty. Check the dirt trap strainer in the oil
return line.
Tab. 66 Other faults and remedies

10 Maintenance
10 Maintenance
Here you will find safety instructions for installation work. Warning notices are immediately before the dangerous action.
Failure to follow the safety instructions can result in life-threatening injuries! ÿ Observe the instructions in section 3 "Safety
and liability
ness".
ÿ Maintenance work must only be carried out by an authorized technician.

staff! ÿ Ensure
that no personnel work on the machine. ÿ Make sure that all maintenance doors and trim
parts are sealed

indoor.

Compressed air has energy. If it is released, life-threatening situations may occur. The following safety instructions apply
to all work on pressurized equipment.
Touching live parts can result in electric shock, burns, or death. Touching the fan impeller, clutch and belt drive while the
machine is running can cause serious injury.

10 Maintenance
10.2 Compliance with maintenance intervals
Additional Information Information regarding authorized personnel can be found in section 3.4.2. Information about dangers and
their prevention can be found in section 3.5.

10.2.1 Documentation of maintenance work
The recommended service intervals apply to original KAESER spare parts used under normal operating conditions.
ÿ Under adverse environmental conditions, maintenance work
needs to be done more frequently.
Unfavorable conditions include:

ÿ high temperature
ÿ a lot of dust
ÿ large number of load switching

ÿ light load
ÿ Adjust the maintenance intervals according to the local environment and

operating conditions.
ÿ Document all preventive and maintenance work.

In this way, you can define individual maintenance intervals that deviate from our recommendations.
Additional Information You will find the prepared sheet in section 10.20.
10.2.2 Resetting the maintenance hour counter

we
Depending on the design, the operating status of important functional parts is monitored by sensors and/or a maintenance
hour counter. Necessary maintenance work is displayed on the SIGMA CONTROL 2 .
Prerequisite Maintenance performed and

maintenance message acknowledged.
ÿ Reset the maintenance hour counter as described in the user manual

SIGMA CONTROL 2 .
10.2.3 Regular maintenance work

The following table shows the required maintenance work. The refrigeration circuit is a closed system. Repair work
may only be carried out by authorized personnel.

10 Maintenance
ÿ Pay attention to the maintenance messages on the control unit and timely
It is important to carry out maintenance work in accordance with the surroundings and the operating
tional conditions:
Interval Maintenance work See section

Weekly Check coolant oil level. Distribution board: 10.13
10.3
check filter mat.
Max. 1,000 h Clean the radiator. Check 10.4
the filter mat for the coolant 10.6

air.
Clean the condenser. Replace 10.19.1
Max. 3,000 h filter mat for coolant 10.6

air.
Distribution board: 10.3

replace filter mat.
Max. 6,000 h Replacement of the repair unit. 10.19.2.2
Display: Replace air filter. Engine bearing 10.8

SIGMA CONTROL 2 10.9
maintenance.
Check clutch. Check the condensate 10.10
drain. 10.19.2
Display: Replace oil filter. 10.17

SIGMA CONTROL 2
at least once in
year
Display: Replace oil separator element. 10.18

SIGMA CONTROL 2
at least once in
3 years
Varies, see table Change cooling oil. zu 68 10.16
h = working hours

10 Maintenance
Interval Maintenance work See section
Annually Safety valve control. Check the safety cut-out when 10.11
10.12
temperature.
Check radiator tightness. Water cooling system 10.4
maintenance. 10.5
Maintenance of the heat recovery system. Check tightness of 10.7

–
all electrical connections.
–
Check (and document) the tightness of the
refining circuit by an authorized service
KAESER service.
–
Check the safety switch
for an authorized service
would be KAESER.
h = working hours
Tab. 67 Regular maintenance work
10.2.4 Coolant oil change intervals
Important criteria for determining the number and duration of replacement intervals
are loading and environmental conditions.
KAESER Service will assist you in establishing the correct

replacement intervals and informs about the possibilities of oil analysis.
ÿ Comply with national laws and/or regulations regarding the use of cooling oil
in screw compressors with oil injection.
ÿ Check the operating conditions, if necessary adjust the replacement interval and
write the results in tab. 68:
Maximum allowable replacement interval

[working hours/years]
SIGMA FLUID Favorable conditions Adverse conditions Own conditions
operation* operating conditions view of operation
S-460 6 000**/2 4 000/1
S-570 6 000**/2 4 000/1
MOL 3 000/1 2 000/1
FG-460 3 000/1 2 000/1
FG-680 3 000/1 2 000/1
PANOLIN HLP SYNTH 3 000/1 2 000/1
46
*
At low and moderate ambient temperatures, low air humidity, high
loading
**
For more than 6000 operating hours, change intervals are set only with the obligatory
oil analysis.
Tab 68 Cooling oil: replacement intervals

10 Maintenance
10.3 Cleaning or replacing the switch cabinet filter mat
10.2.5 Regular maintenance work

The following table provides an overview of the necessary maintenance work. ÿ Maintenance work must
only be carried out by an authorized service
KAESER.
ÿ Carry out preventive maintenance in due time, according to the surrounding and operating conditions:
Interval Preventive work

Display: Check valves.
SIGMA CONTROL 2
Compressor motor: check
motor bearings.
Display: Fan motor: Check motor
SIGMA CONTROL 2 bearings.
at least once every 3
years
Max. 36,000 h Replace connecting hoses: ÿ Pressure
at least once every 6 lines ÿ Control lines ÿ Suction line of
years inlet valve
h = working hours
Tab. 69 Regular preventive maintenance
10.3 Cleaning or replacing the switch cabinet filter mat
The filter mat is installed behind the ventilation grille. It protects the control cabinet from dirt. If the filter
mats are dirty, it is not possible to ensure sufficient cooling of the elements. In this case, the filter mats
must be cleaned or replaced.
Material Warm water with detergent

Spare parts (if necessary)

Let the car cool down.

10 Maintenance
10.4 Radiator maintenance
Rice. 27 Switch cabinet ventilation 1 Ventilation grille 2 Filter mat
1. Carefully remove the ventilation grille and remove the filter mat. 2. Knock out or vacuum the filter mat.
Rinse with warm water if necessary.
water with detergent added to it.
3. If cleaning is not possible or the replacement interval has expired, the filter mat should be
change.
4. Insert the filter mat into the frame and snap the ventilation grille into place.
10.4 Option K1
Radiator maintenance
The radiator should be cleaned regularly. This guarantees reliable cooling of the machine and compressed air. The
frequency of execution depends on the environmental conditions at the installation site.
Radiator leakage leads to loss of oil and compressed air.
Dirt on the radiator is the result of unfavorable ambient conditions. Under such conditions, the cooling system inside
the machine and engine becomes contaminated. Wear increases. ÿ The cooling system must be cleaned by an
authorized KAESER service representative.
Material Brush and vacuum cleaner

Respiratory protection (if necessary)


10 Maintenance
10.5 Water cooling system maintenance
Rice. 28 Cleaning the radiator

1 Radiator 2
Brush
Radiator cleaning
Do not clean the radiators with sharp objects. They may be damaged. Avoid swirling dust. ÿ Clean
the air-oil cooler with a brush and vacuum up the dirt.
If the air - oil cooler is not cleaned. ÿ For heavy soiling,

contact an authorized KAESER service center.
Radiator leak test
ÿ Carry out a visual check for leakage of cooling oil.

If the radiator is leaking: ÿ Have
the defective radiator repaired immediately by an authorized
KAESER Service.
10.5 Option K2/K9

Water cooling system maintenance
Contamination in the radiator leads to elevated temperatures and damage to the machine.
ny.
ÿ It is necessary to monitor the final compression temperature in order to timely

to determine its increase.
Regularly check the tightness and degree of contamination of the radiator. The frequency of checks
depends strongly on the composition of the cooling water.


10 Maintenance
10.6 Cleaning or replacing the cooling air filter mat
Leak test
Generally, the pressure in the cooling oil circulation system is higher than the pressure in the cooling water system. If
a leak occurs, cooling oil may enter the cooling water.
1. Visually check the radiator for leaks. 2. Have the radiator checked for leaks
annually by an authorized KAESER service center.
cleaning
ÿ If the final compression temperature is 10 °C higher than the yearly average, the radiator must be cleaned by an
authorized KAESER service.
10.6 Option K3
Cleaning or replacing the cooling air filter mat
The cooling air filter mat protects the radiator from contamination. If the filter mat is dirty, it will not be possible to
ensure sufficient cooling of the machine.
Material Warm water with detergent Spare part (if required)
Precondition The machine is switched off.
Rice. 29 Cooling air filter mat

1 Cooling air filter mat 2 Mounting frame 3 Clamp
Disassembly:
1. Release clamp 3 : turn the

clamp 90° counterclockwise with a screwdriver.
2. Remove mounting frame 2 .
Cleaning:
ÿ If cleaning is not possible or has been carried out five times, the filter mat must be
update.

10 Maintenance
10.7 Maintenance of the heat recovery system
ÿ Knock out or vacuum the filter mat 1 .

If necessary, rinse with warm water (approx. 40 °C) with detergent added.
Assembly:
ÿ Replace frame and clamps.

Turn the clip 90° clockwise with a screwdriver and press it, the clip should click into place.
10.7 Option W1/W2/W3

Heat recovery system maintenance
Contaminants in the heat exchanger can significantly affect heat transfer. The
tightness and degree of contamination of the heat exchanger must be checked regularly. The
frequency of checks depends on the composition of the coolant. ÿ Have the heat recovery system
inspected by an authorized service
would be KAESER.
10.7.1 Option W1
External heat recovery
ÿ Have the external heat recovery system checked by an authorized KAESER service.
10.7.2 ÿÿÿÿÿ W2/W3

Internal heat recovery system
Generally, the pressure in the refrigeration oil circulation system is higher than the pressure in the
heat recovery system. If a leak occurs, cooling oil may enter the coolant. A significant loss of cooling
oil may indicate a leak in the heat exchanger.

1. Visually check the heat exchanger for leaks. 2. Have the heat exchanger
checked by an authorized KAESER service department and, if dirty, cleaned.
10.8 Replacing the air filter

All seal surfaces are shaped to match. The use of an unsuitable air filter cartridge may
cause dirt to enter the pneumatic system, which in turn can lead to damage to the machine.
Do not clean the air filter element. Using a damaged air filter element may cause dirt to enter
the pneumatic system, which in turn will damage the machine.

10 Maintenance
10.9 Engine maintenance
Material Spare parts

Rice. 30 Air filter maintenance

1 Bolt 2
Air filter cartridge 3 Cover
1. Loosen screws 1 and remove cover 3 .

2. Remove the old air filter cartridge.
3. Clean all parts and sealing surfaces.
4. Insert a new air filter cartridge.
5. Replace the cover and fasten with screws 1 . 6. Close all
maintenance doors and trim panels again. 7. Switch on the mains residual
current device and reset the maintenance hours counter.
living.
10.9 Engine maintenance

Grease nipples for additional lubrication of the motor bearings are located on the outside of the
machine. Grease is charged at the factory.
Use only ESSO UNIREX N3 high temperature grease to lubricate motor bearings. The warranty
does not cover bearing damage resulting from the use of alternative
greases.
Material Grease gun ESSO UNIREX N3 Wiping cloth

10 Maintenance
10.10 Checking the clutch
Rice. 31 Engine maintenance 1 Compressor

motor grease nipples 2 Fan motor grease nipples (if
equipped)
Compressor motor:
The required amount of grease is given on the nameplate of the compressor motor.
Prerequisite Engine running
1. Clean the grease nipple with a cleaning cloth. 2. Lubricate both bearings
with a grease gun. 3. Reset the maintenance hours counter.
Option K1 Fan motor:
Some fan motors are equipped with greased bearings. The amount of grease required for these motors is
indicated on the rating plate of the motor.
hotel.
For fan motors not equipped with relubricated bearings, the bearings are checked by an authorized KAESER
service department as part of a preventive maintenance.
Prerequisite Engine running
1. Clean the grease nipple with a cleaning cloth. 2. Lubricate both bearings
with a grease gun. 3. Reset the maintenance hours counter.
Option K2 / K9 Fan motor:
ÿ Have the fan motor checked by an authorized KAESER service center as part of maintenance work.
10.10 Checking the clutch

Clutch failure is recognized by:
ÿ rough running
ÿ surface cracks
ÿ color change

10 Maintenance
10.11 Checking the safety valve
WARNING Risk of
injury from a rotating clutch! ÿ Never start the machine without the
clutch guard.
niya.
Rice. 32 Clutch check 1 Safety grill 2

Clutch
Visual check for smooth running
Prerequisite The machine is running
ÿ Visually check that the clutch runs smoothly.
Visual damage control

The car is cold.
1. Unscrew the safety grille. 2. Turn the clutch

by hand and check for damage and changes
colors.
3. Replace the safety grille. 4. Close all maintenance doors
and trim parts.
If cracks or discoloration are found on the clutch. ÿ Have the defective clutch
replaced by an authorized service
KAESER service.
10.11 Checking the safety valve

In order to check the safety valve, the excess pressure of the machine must be raised above the
set pressure.

10 Maintenance
10.12 Checking the safety shutdown at elevated temperature
During the test, network pressure control is switched off. In normal operation, the overpressure protection shuts down the
machine before the safety valve opens. During the test, the overpressure protection switches off the machine as soon as the
opening pressure of the safety valve is exceeded by 1 bar.
ÿ Please note the detailed description of this process in the user manual.
using SIGMA CONTROL 2 .
ÿ The machine may only be operated with a functional safety

valve.
ÿ A defective safety valve must be replaced immediately.
WARNING Hearing injuries

can occur if the safety valve is activated! ÿ Close all service doors and trim panels. ÿ Wear hearing protection.
Precondition The machine is switched off.
1. Close the shut-off valve (installed by the user) between the machine and the pneumatic
tew.
2. Record the set pressure indicated on the relief valve.

(Typically set pressure is listed last on the relief valve label)
3. Enter the password for access level 2 in SIGMA CONTROL 2 . 4. Check the
pressure indication on the SIGMA CONTROL 2 and call the test mode.
5. WARNING! Risk of burns from

cooling oil and compressed air when venting through the safety valve! ÿ Close all service doors and trim panels. ÿ Wear
safety goggles.
6. Stop the test immediately as soon as the safety valve opens or the overpressure exceeds the set pressure by more
than 1 bar.
7. If necessary, bleed the machine and replace the defective fuse.

body valve.
8. Deactivate test mode. 9. Open the user-installed
shut-off valve between the machine and the compressed air network.
10.12 Checking the safety shutdown at elevated temperature
When the maximum compression end temperature of 110 °C is reached, the machine must
turn on.
ÿ Check the safety shutdown as described in the instructions for use

SIGMA CONTROL 2 .
If the machine does not turn off:
ÿ have the safety cut-out checked by an authorized KAESER service.

10 Maintenance
10.13 Checking the cooling oil level
10.13 Checking the cooling oil level

On machines with a frequency converter (SFC), the oil level indicator shows the correct oil
level only when the speed is close to maximum. The lower the pressure at the compressed
air outlet of the machine, the higher the speed. This value is displayed on SIGMA CONTROL
2.
Prerequisite The machine has been running for at least 5 minutes under LOAD.
Rice. 33 Checking the cooling oil level

1 Minimum oil level 2 Maximum oil
level 3 Optimum oil level
1. WARNING!
Risk of burns from touching hot surfaces! ÿ Wear long sleeves and protective
gloves.
2. Check the cooling oil level with the engine running under LOAD.
rails.
Result If the cooling oil level has dropped to the bottom mark "Minimum oil level"
sla": add cooling oil.
10.14 Depressurizing the machine

Depressurization of the machine is carried out manually in three steps: ÿ
The machine must be disconnected from the pneumatic network. ÿ
Discharge of compressed air from the oil separator. ÿ Discharge
compressed air from the air cooler manually.
Before carrying out any work related to opening the pneumatic system, the machine must
be disconnected from the pneumatic network and not under pressure.

10 Maintenance
10.14 Depressurizing the machine
Material Required pressure relief nozzle with stopcock and service hose
niya are located under the oil separator.

CAUTION Emitted
oil vapors are harmful to health! ÿ When relieving pressure, the
service hose must not be directed towards

of people.
ÿ Do not inhale oil vapours.
Rice. 34 Depressurizing the machine
1 Hose coupling (air cooler pressure relief) 2 Pressure 7 Shut-off valve

gauge 3 Hose coupling (oil separator pressure A Shut-off valve open
relief) 6 Nozzle B Shut-off valve closed 8 Maintenance
hose
Disconnecting the machine from the pneumatic network
ÿ Close the shut-off valve (installed by the user) between the machine and the pneumatic
tew.
If the user has not installed a shut-off valve, compressed air must be removed from the entire pneumatic network.
Discharge of compressed air from the oil separator
As soon as the machine is switched off, air is automatically purged from the oil circulation system.
ÿ Check whether the pressure gauge on the oil separator tank shows 0 bar.

10 Maintenance
10.15 Topping up cooling oil
If the pressure gauge does not show 0 bar after automatic venting: ÿ Make sure that the shut-off valve is
closed or that the entire pneumatic system has been depressurized. ÿ Insert the nozzle 6 with the stopcock closed
into the hose socket 3 . ÿ Slowly open shut-off valve 7 and release any residual pressure. ÿ Remove nozzle 6 again
from the hose coupling and close the shut-off
crane 7 .
ÿ If the pressure gauge does not show 0 bar after manually depressurizing the oil separator: contact an authorized
KAESER service.
Releasing compressed air from the air cooler manually
After the oil separator has been switched off and bled, the machine is pressurized from the compressed air system
(or shut-off valve) to the minimum pressure check valve.
1. Insert the nozzle 6 with the stopcock closed into the hose socket 1 . 2. Slowly open shut-off valve 7
and remove residual pressure. 3. Remove the nozzle 6 again from the hose coupling and close the shut-
off valve 7 .

Before carrying out any work related to opening the pneumatic system, the machine must be disconnected from
the pneumatic network and not under pressure.
Material Required pressure relief nozzle with stopcock and service hose
niya are located under the oil separator.


10 Maintenance
Rice. 35 Adding cooling oil 1 Hose coupling (air

cooler pressure relief) 2 Pressure gauge 3 Hose coupling 6 Nozzle 7
(oil separator pressure relief) 4 Oil filler with screw Stopcock
plug 5 Oil level gauge A Shut-off valve open
B Shut-off valve closed 8
Maintenance hose
1. Bleed the machine as described in section 10.15.1. 2. Add cooling oil and carry
out a test run as described in section
and 10.15.2.
10.15.1 Depressurizing the machine

Depressurization of the machine is carried out manually in three steps: ÿ The machine
must be disconnected from the pneumatic network. ÿ Discharge of compressed air
from the oil separator. ÿ Discharge compressed air from the air cooler manually.
CAUTION Emitted
oil vapors are harmful to health! ÿ When relieving pressure, the
service hose must not be directed towards
people.
ÿ Do not inhale oil vapours.
Disconnecting the machine from the pneumatic network
ÿ Close the shut-off valve (installed by the user) between the machine and the pneumatic
tew.
If the user has not installed a shut-off valve, compressed air must be removed from the entire pneumatic network.

10 Maintenance
Discharge of compressed air from the oil separator
As soon as the machine is switched off, air is automatically purged from the oil circulation system.
ÿ Check whether the pressure gauge on the oil separator tank shows 0 bar.
If the pressure gauge does not show 0 bar after automatic venting: ÿ Make sure that
the shut-off valve is closed or that the entire pneumatic system has been depressurized. ÿ
Insert the nozzle 6 with the stopcock closed into the hose socket 3 . ÿ Slowly open shut-off
valve 7 and release any residual pressure. ÿ Remove nozzle 6 again from the hose coupling
and close the shut-off
crane 7 .
ÿ If the pressure gauge does not show 0 bar after manually depressurizing the oil separator:
contact an authorized KAESER service.
Releasing compressed air from the air cooler manually
After the oil separator has been switched off and bled, the machine is pressurized from the
compressed air system (or shut-off valve) to the minimum pressure check valve.
1. Insert the nozzle 6 with the stopcock closed into the hose socket 1 . 2. Slowly
open shut-off valve 7 and remove residual pressure. 3. Remove the nozzle 6 again
from the hose coupling and close the shut-off valve 7 .
10.15.2 Topping up the cooling oil and performing a test run

Topping up cooling oil
A sticker indicating the type of coolant filled in is located on the oil separator tank.
1. WARNING! Compressed
air! Compressed air or
pressurized components, due to the energy released during disassembly or removal, can
cause serious injury or death.
ÿ Ensure that all pressurized components and containers are free of pressure.
laziness.
2. NOTE!
Possible damage to the machine due to incompatible cooling oils! ÿ Never mix different
types of cooling oil. ÿ When adding oil, use the same type of oil that is already filled in
the machine.
3. Slowly unscrew plug 4 on the filler pipe. 4. Add the required
amount of oil. 5. If necessary, change the gasket on the screw
cap, and then close
filler pipe plug.
Putting the machine into operation and carrying out a trial run
1. Close all maintenance doors and trim panels. 2. Open the user-
installed shut-off valve between the machine and the compressed air network.

10 Maintenance
10.16 Changing the cooling oil
3. After 10 minutes of operation: check the cooling oil level and, if necessary,
add oil.
4. Switch off the machine and carry out a visual leak test.

Completely drain the cooling oil from the following: ÿ Oil separator ÿ
Oil cooler ÿ Compressor block ÿ Heat recovery systems (options
W1/W2/W3)
ÿ When changing the cooling oil, always change the oil filter and
oil separator element.
ÿ If condensation is found in the cooling oil, contact the service
KAESER service. The final compression temperature must be adapted to the individual
operating conditions.
The cooling oil is drained under pressure using compressed air. This pressure is generated either
by the machine itself, or compressed air is supplied to the machine from outside.
Compressed air from an external source is required in the following cases, for example: ÿ the
machine is not in operation, ÿ when the machine is put into operation after a long stop.
Material Coolant oil Reservoir for

draining the cooling oil The nozzle with shut-
off valve and service hose required for venting are located under the oil separator.
CAUTION
Danger of burns from hot parts and hot oil! ÿ Wear long sleeves and protective gloves.

10 Maintenance
Rice. 36 Coolant oil change, oil separator

1 Hose coupling (air cooler pressure relief) 2 A Shut-off valve open
Pressure gauge 3 Hose coupling (oil B Shut-off valve closed 8
separator pressure relief) 4 Oil filler with screw Service hose 9 Hose coupling (oil
cap 5 Oil level gauge 6 Nozzle 7 Shut-off cock drain) 10 Shut-off valve (vent line) 11
Shut-off valve (oil drain)

10 Maintenance
Replacing the cooling oil with its own pressure Replacing the cooling oil with an external compressed
air source
The machine must be operated for at least 5 minutes under The mains residual current device is completely de-
LOAD. Depressurize the machine, the pressure gauge on energized,
the oil separator must show 0 bar. 1. Close shut-off valve measures taken against unintentional
10 on the pressure relief line. 2. Set IDLE. 3. Switch on the inclusions,
machine and check pressure gauge 2 on the oil separator no voltage has been checked.
until it reads 3–5 bar. 4. Disconnect the machine (residual

current circuit breaker) completely, secure against Depressurize the machine, the pressure
gauge on the oil separator must show 0 bar. Prepare an
unintentional switching on, check that there is no voltage.
external compressed air source.
1. Close shut-off valve 10 on the pressure relief line.

2. Insert the nozzle 6 with the stopcock closed
into the hose socket 3 . 3. Service hose connect
5. Wait at least 2 minutes for the cooling oil to drain thread to an external compressed air source.
back into the oil separator reservoir.
4. Open the stopcock and check the pressure gauge 7 on the
oil separator tank until it shows 3–5 bar.
5. Close stopcock 7 and remove the nozzle from the hose

coupling.
Draining the cooling oil from the oil separator
1. Prepare a container for draining the cooling oil. 2. Insert the nozzle 6 with
the stopcock closed into the hose socket 9 . 3. Lower the service hose into an oil drain container and
secure it. 4. Open shut-off valve 11 . 5. Slowly open stopcock 7 on the service hose, drain the oil and
close the air outlet immediately.
6. Close stopcock 11 and remove the nozzle.

10 Maintenance
Draining the cooling oil from the oil cooler
Rice. 37 Coolant oil change, oil cooler 6 Nozzle 7 Shut-off valve

1 Oil cooler 2 Hose
coupling (oil drain) 3 Shut-off valve
1. Prepare a container for draining the cooling oil. 2. Insert the

nozzle 6 with the stopcock closed into the hose socket 2 . 3. Lower the service hose
into an oil drain container and secure it. 4. Open shut-off valve 3 . 5. Slowly open shut-off
valve 7 air until the pressure gauge on the oil separator shows 0 bar.
, completely remove the cooling oil and compressed
6. Close stopcock 2 and remove the nozzle.
Draining the cooling oil from the compressor unit
Rice. 38 Changing the cooling oil, compressor unit 1

Compressed air outlet of the compressor unit 2 4 Protective grille 5 Clutch
Hose coupling (oil drain) 3 Shut-off valve

10 Maintenance

nozzle 6 (Fig. 36) with the shut-off valve closed into the hose coupling 2 . 3. Lower the service
hose into an oil drain container and secure it. 4. Open stopcocks 3 and 7 (Fig. 36). 5. Remove
the safety grille 4 and manually turn the clutch 5 (minimum
at least 5 turns) until the cooling oil is completely drained. 6. Install the
safety grille again. 7. Close stopcock 3 and remove the nozzle.
Result The cooling oil has been drained from the compressor unit.
When the clutch is rotated, it is possible that a small amount of cooling oil will flow back into the
radiator and oil separator. To drain this oil, repeat the steps of "Draining the cooling oil from the oil
separator" and "Draining the cooling oil from the oil cooler" again.
Option W1 Draining the cooling oil from the external heat recovery system
If an external heat recovery system is connected to the machine, the oil from the heat exchanger
must also be drained.
Prerequisite No pressure in the external heat recovery system.
1. Prepare a container for draining the cooling oil. 2. Open the

external heat recovery system and completely drain the cooling oil. 3. Close the external heat
recovery system tightly again.
ÿÿÿÿÿ W2/W3 Draining the cooling oil from the internal heat exchanger
Rice. 39 Cooling oil change, heat recovery system

1 Hose coupling 2
Thermal valve 3
Stopcock

nozzle 6 (Fig. 36) into the hose coupling 1 . 3. Lower the
service hose into an oil drain container and secure it.

10 Maintenance
10.17 Changing the oil filter element
4. Open stopcocks 3 and 7 (Fig. 36) and completely drain the cooling oil. 5. Close stopcock
3 and remove the nozzle.
Cooling oil filling
laziness.
2. Slowly unscrew plug 4 (Fig. 36) on the filler pipe. 3. Fill in cooling oil.
4. Check the plug gasket for damage, and then plug the filler
branch pipe.
installed shut-off valve between the machine and the compressed air network. 3. Switch on the
mains residual current device and reset the maintenance hour counter.
living.
4. Switch on the machine, check the cooling oil level after about 10 minutes and top up if necessary.
ÿ Dispose of the cooling oil in accordance with the applicable environmental regulations.
10.17 Changing the oil filter element


Cleaning material

Depressurize the machine, the
pressure gauge on the oil separator should show 0 bar.
CAUTION
Danger of burns from hot parts and hot oil! ÿ Wear long sleeves and protective gloves.

10 Maintenance
10.18 Replace oil separator element
Rice. 40 Changing the oil filter

1 Oil filter element 2 Direction of rotation
when unscrewing the filter
Replacing the oil filter element
the outcome.
laziness.
2. Unscrew the filter cover. 3.

Remove the old oil filter element and dispose of according to environmental regulations.
requirements.
4. Install a new oil filter element. 5. Screw the filter
cover back into place, taking into account the tightening torque.
ÿ Work materials and components contaminated with cooling oil must be disposed of
vat according to environmental requirements.
living.
4. After 10 minutes of operation: Check the cooling oil level and, if necessary,
it is possible to add oil.

The oil separator element must not be cleaned.

10 Maintenance
The service life of an oil separator element depends on: ÿ impurities in the intake air; ÿ
change intervals: ÿ Coolant oil ÿ Oil filter ÿ Air filter

Cleaning material

Depressurize the machine, the
pressure gauge on the oil separator should show 0 bar.
Rice. 41 Replace oil separator element 14 Cover 15 Dirt trap

16 Air line 17 Fixing bolt 19 Nut (self-locking) 20
Threaded connection 21
Gasket 23 Oil separator
cartridge
Replace oil separator element
laziness.
2. Unscrew the screw connection 20 , carefully remove the fittings with connections and pull out the
pipe, position 15 .

10 Maintenance
10.19 Refrigeration dryer maintenance
3. Unscrew the nuts 19 and turn the air tube 16 to the side. 4. Unscrew the
bolts 17 on the cover 14 of the oil separator and carefully remove the cover. 5. Pull out the
old replacement element 23 together with the seals 21 and dispose of it in an environmentally
friendly manner.
6. Clean all sealing surfaces. 7. Insert a new oil separator
element with new gaskets and secure
cover.
8. Replace strainer and dirt trap O-ring 15 . 9. Fasten the air pipe to the cover with
14 new nuts (self-locking). 10. Replace the removed screw connections and tighten.
ÿ Work materials and components contaminated with cooling oil must be disposed of
vat according to environmental requirements.
living.
4. After 10 minutes of operation: switch off the machine and carry out a visual check on the pressure
accuracy.

The refrigeration circuit is a closed system. Repair work may only be carried out by authorized
personnel.
Material Brush and vacuum

cleaner Respiratory protection (if necessary)
Rice. 42 Refrigeration dryer 1

Condenser 2 Brush

10 Maintenance
10.19.1 Cleaning the condenser

Do not clean the condenser with sharp objects. Risk of damaging the capacitor.
Avoid swirling dust.

ÿ Clean the condenser with a brush and vacuum up the dirt.
If the condenser cannot be cleaned: ÿ Contact an

authorized KAESER service to remove heavy dirt.
10.19.2 Maintenance of the condensate drain

Condensate is drained through 2 condensate drains:
ÿ on the cyclone separator
ÿ on the refrigeration dryer separator
10.19.2.1 Check the condensate drain
Precondition The machine is switched off. Light-

Power glows.
emitting diode
Rice. 43 Check condensate drain

1 LED 2 TEST Power
button 3 LED
Alarm
1. WARNING!
Danger of burns from hot components in the vicinity of the condensate drain! ÿ Work with precautions.
2. Grasp the hose on the condensate drain with one hand. 3. With the other hand,
press and hold down the "TEST" button on the condensate drain for at least 2 s.
Result When you open the condensate drain, you will feel pressure in the hose.
If no pressure is felt in the hose during the test, the condensate drain must be serviced.

10 Maintenance
10.19.2.2 Maintenance of the condensate drain
The condensate drain must not be cleaned. If the condensate is not drained, the repair unit must be
replaced.

Light-emitting diode Power do not glow (see fig. 43)
Rice. 44 Condensate drain maintenance

1 Repair assembly 2 6 Drain hose adapter 7 Springs 8 Inlet 9
Control board 3 Sensor 4 Stopcock
Sensor hole 5 Retainer
Dismantling the repair unit
1. Close shut-off valve 9 in front of the condensate drain. 2. Unscrew the drain hose
adapter. 3. Press latch 5 and carefully remove the control board from the repair unit.
4. Carefully disconnect the pipeline at the inlet of the repair unit.
Installation of the repair unit
The functionality of the condensate drain can only be guaranteed if a KAESER repair unit is used.
Prerequisite The top surface of the repair assembly and the springs are dry and clean.
1. Connect the pipeline to the inlet of the repair unit. 2. Carefully

insert sensor 3 of the control board into hole 4 on the new repair
nom node.
3. Insert the hooks of the control board into the slots on the repair node and on the other side
snap the control board into the fixing of the repair unit.
4. Install the drain hose and open the shut-off valve 9 in front of the drain
condensate.
5. Close all maintenance doors and trim panels.

10 Maintenance
10.20 Documentation of preventive and maintenance work
10.20 Documentation of preventive and maintenance work

Machine number:
ÿ Registration of carried out preventive and maintenance work:
Date Maintenance work Operating hours Signature

vanity
Tab. 70 Registered maintenance work

11 Spare parts, operating fluids,
Maintenance
11.1 Pay attention to the rating plate

Maintenance
11.1 Pay attention to the rating plate
The rating plate contains information to identify your machine. This in-
The formation is necessary to provide you with appropriate technical support.
ÿ When placing an order for spare parts or questions regarding equipment,
nameplate data must be entered.
11.2 Ordering spare parts and consumables

Spare parts and operating materials from KAESER correspond to the original
nym. They are designed for use in our machines.
Spare parts and operating materials of inadequate or poor quality may
cause damage to the machine or significantly reduce its performance.
Personnel may be injured if the machine is damaged.
WARNING
Risk of personal injury or damage to the machine due to unsuitable
spare parts and operating materials!
ÿ Only use original spare parts and the specified operating
materials.
ÿ Carry out regular maintenance by an authorized service
KAESER.
Machine
Name pieces/quantity Number
Air filter cartridge Filter mat 1 1250
(camera 2 1100
fa)
Filter mat (option K3) Oil filter 2 1050
1 1200
Replaceable oil separator element 1 1450
Cooling oil 1 1600
Bearing grease [g] 100 9.0915.0

400 6.3234.0
Tab. 71 Spare parts for machine maintenance
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE provides you with:
ÿ service by authorized service technicians trained in
company KAESER,

11 Spare parts, operating fluids, maintenance
11.4 Coordinates of service centers
ÿ increased operational reliability due to damage prevention,

ÿ saving energy by preventing pressure losses,
ÿ optimal conditions for the operation of the pneumatic station,
ÿ reliability thanks to original KAESER spare parts, ÿ increased legal guarantees due to
compliance with regulations.
ÿ Sign a KAESER AIR SERVICE service agreement.
The result Winning - low

costs and trouble-free compressed air production.
11.4 Coordinates of service centers

At the end of these operating instructions, you will find the addresses of KAESER worldwide.
11.5 Spare parts for maintenance and repair

Using this spare parts list, you can plan the need for materials depending on operating conditions, as well as order
the necessary spare parts.
parts.
ÿ Inspection, maintenance and repair work on the machine that is not described in these operating
instructions may only be carried out by an authorized KAESER service center.

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

12.1 Decommissioning
12.1 Decommissioning
For example, decommissioning is necessary in the following cases: ÿ The
machine will not be used for an extended period. ÿ Transporting the machine
to another location. ÿ The machine must be scrapped.
Temporary decommissioning
Prerequisite The machine must be switched on at regular intervals.
ÿ To ensure effective corrosion protection, run the machine weekly for about 30 minutes in LOAD
mode.
Decommissioning for a long period
Prerequisite Immediately prior to decommissioning, the machine has been operated for at least 30 minutes in
LOAD mode. The
machine (mains residual current device) is completely de-energized, measures
have been taken against unintentional switching on, and a voltage absence test
has been performed.
The pressure in the car has been released.
1. Let the machine cool down

completely. 2. Turn off all piping and power.
12.2 Packaging
For land transportation, a wooden crate is required to protect the machine from mechanical
damage. For transportation by sea and air, additional measures are necessary. For details,
contact your authorized KAESER service center.
Material Dehumidifier Protective

film Crate as
transport packaging
Prerequisite The machine has been taken out of service.

The machine is dry and cool.
1. Ensure that there is a sufficient amount of product inside the machine

dehumidification (kieselguhr or activated clay). 2.
Wrap the machine completely with protective film. 3.
Provide for the protection of the machine from mechanical damage with a wooden
crates.

12.3 Storage
12.3 Storage
Humidity causes corrosion, especially on the surfaces of the compressor block and oil separator.
Frozen moisture can damage components, valve diaphragms and seals. The following measures
also apply to machines that have not been put into operation.
Consult KAESER for proper storage and commissioning.
1. NOTE!
Damage to the machine due to humidity and low temperatures!
ÿ Prevent the ingress of moisture and condensation. ÿ Observe the required
storage temperature > 0 °C.
2. Place the machine in a dry and warm room.
12.4 Transport
12.4.1 Security
The required vehicle is determined by weight and center of gravity. The center of gravity is shown on
the outline drawing in section 13.3.
ÿ For transporting the machine in frosty weather, consult a specialist
KAESER sheets.
Prerequisite Transportation is carried out only with a forklift or handling equipment and only by specially trained personnel who are
authorized to safely transport goods.
ÿ Ensure that no one is in the danger area.
12.4.2 Transporting the machine with a forklift
Prerequisite The machine must be stable on the forks of the forklift.
Rice. 45 Transport by forklift
ÿ Guide the forks of the forklift as far as they will go under the machine or transport pallet and
raise carefully.

12.5 Disposal
12.4.3 Transporting the machine with a crane
Reliable transport is carried out by means of a loading and unloading device

things.
Pass the lifting straps under the machine. They should not
put pressure on the body.
Examples for unsuitable attachment points:

ÿ fitting
ÿ Flanges ÿ
Installed devices such as cyclone separator, steam trap or
filters.
ÿ rain protection
ÿ Consult KAESER for the correct use of the handling device.
Prerequisite The handling device complies with local safety regulations.

No lateral loads on the machine body.
Rice. 46 Transport by crane

1 Handling device 2 Webbing slings
1. NOTE!
Damage to the machine due to incorrect attachment of the loading and unloading device! ÿ It
is not permitted to attach the handling device to machine components.
2. Using the proper handling device, carefully

lift the car.
12.5 Disposal
When disposing of the machine, all consumables and dirty filters must be removed.

12.5 Disposal
Prerequisite The machine has been taken out of service.
1. Completely drain the cooling oil from the machine. 2.

Remove oil separator cartridge and dirty filters. 3. Hand over the machine to a
specialized disposal company.
ÿ Dispose of components contaminated with cooling oil in accordance with environmental
regulations.
On machines with a refrigeration dryer:
The sealed refrigeration circuit of the refrigeration dryer also contains refrigerant and oil. ÿ The
refrigerant and oil must be drained and disposed of by a specialist company.
tiem.

13 Appendix
13.1 Technological scheme of pipelines and tools (R + I - scheme)
13 Appendix
13.1 Technological scheme of pipelines and tools (R + I -
scheme)

13 Appendix

13 Appendix

13 Appendix

13 Appendix

13 Appendix

13 Appendix
Technological scheme of pipelines and tools (R + I-scheme)
13.2 PARTIAL LOAD control
13.2 Option C1
Technological scheme of pipelines and tools (R+I scheme)
PARTIAL LOAD control

13 Appendix

13 Appendix

13 Appendix

13 Appendix

13 Appendix

13 Appendix
13.3 Dimensional drawing

ñâíóòðåííûì
âòîðè
÷
íûì
èñïîëüçîâàíèåì
òåïëà
ÿt
=
25K
âòîðè
÷
íûì
òåïëà
ÿt
=
55K èñïîëüçîâàíèÿ
âòîðè
÷íîãî ôèëüòðîâàëüíûå
ìàòû
äëÿ
âîçäóõà
îõëàæäàþùåãî
òåïëà ïîäãîòîâëåí
äëÿ
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÷
åííûå
íîæêè
ìàøèíû îïöèÿ:
72
S
1290
1150 1006
1350
K3
FROM
âîçäóõà
ïîäà÷à
Îáîçíà÷åíèå:
In
3 In
2 In
1 K
3 K
1 H
1
Ìèíèìàëüíàÿ
øèðèíà
ñîîòâåòñòâóåò
îòêðûòèÿ
øèðèíå
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+
100
ìì ÍÈÅÌÀÍÈÅ! â
çàâèñèìîñòè
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îò S:
öåíòð
òÿæåñòêè
çèöèÿ
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èçìåíÿåòñÿ
650
970 140
1073
90° 90°
S 2350
W1
2510
G
11/4
W2
W3 1145
988
âîçäóõà
âûõîä
140
1350
90°
Y 240
90° ideas íèïïåëü
ïîäøèïíèêàìàçî÷íûé
1080
ïðèñîåäèíåíèå
ñæàòîãî
âîçäóõà
G2
145
ñïóñê
êîíäåíñàòà
G
1/4
Y
100
áîðó ýëåêòðè
÷
åñêèå
4
xØ26 2
xØ58
166
204
Status Document
TZD TZM Change
no.
APPROVED 10219384
D
00 10219384
R00 document28166
A
projection
990
CSDX.3
T
K1 designation A2 Original scale
190
A
âèä
released edit signed
150
ýëåêòðè÷åñêèå
áîðó ïðèñîåäèíåíèÿ
02.04.2012 29.03.2012
04.04.2012
Datum
SCHUBT4 ROEBLITZ1 ROEBLITZ1 1068
FROM
Name
140
170
13 O
R language
H1
1out
of
1 Blatt
Dimensional drawing
13 Appendix 13.3
âòîðè
÷
íûì
òåïëà
ÿt
=
55K ñâíóòðåííûì
âòîðè
÷
íûì
òåïëà
ÿt
=
25K ïîäãîòîâëåí
äëÿ
ñèñòåìû
âòîðè
÷
íîãî
èñïîëüçîâàíèÿ
òåïëà ïðèâèí
÷
åííûå
íîæêè
ìàøèíû îïöèÿ:
72
S
1290
1150 1006
FROM
ïîäà
÷
à
âîçäóõà
Îáîçíà÷åíèå:
K
2
K
9/
In
3 In
2 In
1 H
1
Ìèíèìàëüíàÿ
øèðèíà
ñîîòâåòñòâóåò
îòêðûòèÿ
øèðèíå
óñòàíîâêè
+
100
ìì ÍÈÅÌÀÍÈÅ! â
çàâèñèìîñòè
èçãîòîâëåíèÿ
îò S:
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òÿæåñòêè
çèöèÿ
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èçìåíÿåòñÿ
650
970
1250
90° 90°
1928
140
S 2350
2510
W1 1145
âûõîä
âîçäóõà
G
11/4
W2
W3
1350 90°
G
11/4
90° K2
K9
87 140
Y 240
90° ideas íèïïåëü
ïîäøèïíèêàìàçî÷íûé
1080
ïðèñîåäèíåíèå
ñæàòîãî
âîçäóõà
G2
145
ñïóñê
êîíäåíñàòà
G
1/4
Y
100
166
Identify
÷
åïïèäääää
204
4
xØ26 2
xØ58
Status Document
TZD TZM Change
no.
APPROVED 10219531
D
00 10219531
R00 document28166
A
projection
CSDX.3
T
K2
K9 designation A2 Original scale
190
A
âèä
02.04.2012 02.04.2012
05.04.2012
Datum
150
Identify
÷
åïïèäääää
SCHUBT4 ROEBLITZ1 ROEBLITZ1
FROM
Name
13 O
140
170
R language
H1
page
1of
1
Dimensional drawing
13 Appendix 13.3
CSDX
140/165
K1
CSDX
140/165
K2/
K9
ÿpmax.
30
Pa
(3
mm
âîäÿíîãî
ñòîëáà)
CSDX
165
V
=
13.000
m³/
h : CSDX
140
V
=
11.000
m³/
h :
. .
äîïóñòèìàÿ
ïîòåðÿ
îáùàÿ
äàâëåíèÿ
äëÿ
ïðèñîåäèíèòåëüíûõ
êàíàëîâ
ÿp
max.
60
Pa
(6
mm
ÿÿÿÿÿÿÿ
ÿÿÿÿÿ
ÿÿÿÿÿÿÿÿÿÿÿÿÿÿ
ÿÿÿÿ
ÿÿÿÿÿÿÿÿ
ÿÿÿÿÿÿÿÿÿ
ÿÿÿÿÿÿ
ÿÿÿÿÿÿÿÿÿÿ
ÿÿÿÿÿÿÿÿÿÿÿÿÿÿÿÿ)
988 990
âîçäóõà îõëàæäàþùåãî âûõîä
áåç
ôèëüòðîâàëüíûõ
ìàò
âîçäóøíîå
îõëàæäåíèå
673 668
1073 1068
ñôèëüòðîâàëüíûìè
ìàòàìè
-
CSDX
140
V
=
9.600
m³/
hCSDX
165
V
=
11.600
m³/
h :: âîçäóõà îõëàæäàþùåãî ïîäà÷à
. .
T11422.00 Technical
Service
No. 10204819
D
00 Document
no. Index
Change
no.
CSDX
140/165
V
=
1.400
m³/
h :
âîäÿíîå
îõëàæäåíèå
CSDX
140/165 designation A3 Original scale
.
09/14/11
14.09.11
315
Datum
âîçäóõà îõëàæäàþùåãî âûõîä
ïðèñîåäèíèòåëüíûõ
êàíàëîâ äàâëåíèÿ
äëÿ äîïóñòèìàÿ
ïîòåðÿ
îáùàÿ
Schubart,
P.
850
Roeblitz1
Name 1250
R language
Blatt
13 Appendix
13 Appendix
13.4 Wiring diagram
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram

13 Appendix
13.4 Wiring diagram


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CSDX T SIGMA CONTROL 2

Screw Compressor Instruction Manual

Screw Compressor Instruction Manual

8.1.2 Shutdown ............................................... ................................................. ...... 67 8.2

10.2.3 Regular maintenance work ............................................................... ...................... 76

Screw Compressor Instruction Manual

12.4 Transport .................................................................. ................................................. .......... 116

Screw Compressor Instruction Manual

Rice. 1 Maximum relative humidity of intake air .............................................. 6 fig. 2 Location of

Screw Compressor Instruction Manual

Screw Compressor Instruction Manual

operation ................................................. ................................................. .........................

Screw Compressor Instruction Manual

Tab. 54 Energy-saving types of regulation ............................................................... ...............................

Screw Compressor Instruction Manual

each subsequent owner or

plate and the individual features of the machine

1.2 Additional documents

Missing documents can be ordered from KAESER. ÿ Check the

1.4 Symbols and conventions

1.4.1 Warning instructions

Signal word Meaning Consequences for non-compliance

Screw Compressor Instruction Manual

Signal word Meaning Consequences for non-compliance

Tab. 1 Hazard levels and their meaning (danger to personnel)

1.4.2 Warnings for property damage

You can recognize material damage warnings by the signal word:

Signal word Meaning Consequences in case of non-

Tab. 2 Danger levels and their meaning (material damage)

Screw Compressor Instruction Manual

damage are described here.

ÿ Read the warnings carefully and follow them strictly.

1.4.3 Additional information and symbols

Information about potential problems is indicated by an interrogative

The supporting text states the reason...

This symbol indicates important information or measures to protect the environment.

Screw Compressor Instruction Manual

The rating plate is located on the outside of the machine:

ÿ Enter the nameplate data here:

Tab. 3 Rating plate

Option Designation In stock?

Partial load control C1

Heat recovery system ÿT=25 K W2

Screw Compressor Instruction Manual

Option Designation In stock?

Heat recovery system ÿT=55 K W3

CSDX 140 CSDX 165

Weight, kg] 2045 2140

Tab. 5 Machine weight

switch-on temperature [°C]

Maximum ultimate 110 110

2.5 Ambient conditions

Max Height 1000 1000

Screw Compressor Instruction Manual

Rice. 1 Maximum relative humidity of intake air

CSDX 140 CSDX 165

Ventilation opening Z see 2,3 / 0,8* 2,7 / 0,8*

Safety valve set pressure at 50 Hz [bar]:

Maximum operating CSDX 140 CSDX 165

15,0 16* 16*

Screw Compressor Instruction Manual

Maximum excess CSDX 140 CSDX 165