Manual de Servicio ASD-T

SERVICE MANUAL
Screw Compressor
Model: ASD T Dual Voltage
No.: 9_5721_02USE
Contents
Chapter --- page
Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1
1.2
1.3
1.4
1.4.1
1.4.2
-------------
1
1
1
1
1
2
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free air delivery (FAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Oil Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Heat Recovery (option W2 / W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
-----------------------------------
3
4
4
4
4
5
5
5
5
5
6
6
7
7
7
8
10
Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11

3.1
3.2
3.3
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.6
3.7
3.7.1
3.7.2
3.7.3
3.8
1
1
1
1
1
1
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.7.1
2.7.2
2.8
2.8.1
2.8.2
2.9
2.9.1
2.9.2
2.10
2.11
Handling the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols and Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous notices and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Users Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from released spring force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from released compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire supression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
---------------------------------
11
11
11
12
12
12
12
13
13
13
14
14
14
14
14
15
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16

4.1
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
Contents
Chapter --- page
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.5
16
16
19
19
19
19
19
20
20
20
20
21
21
21
22
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Place of installation and space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in a compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
5
-----------
24
24
24
25
25
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Report Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing main voltage connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat recovery system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
6
6
6
6
-------------------
26
26
26
27
27
31
31
31
31
Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 33

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
-------------------------------
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.1
6.2
6.3
6.4
6.4.1
6.5
6.6
6.6.1
6.6.2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24

5.1
5.2
5.2.1
5.2.2
5.2.3
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine mountings (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat panels (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional filter monitoring set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulating control (option C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL Keys and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Initial Start ---up (or Recommissioning) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the overload protection cut ---out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protection Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pour Cooling Oil into the Inlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
7
7
7
7
-----------------
33
33
33
34
34
35
35
36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37
8.1
Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37
ii
Contents
Chapter --- page
8.1.1
8.1.2
8.1.3
8.2
8.3
8.4
8.5
8.5.1
8.5.2
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching Off in an Emergency and Switching On Again . . . . . . . . . . . . . . . . .
Remote On and Off Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on and off with the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . .
Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
8
8
8
8
8
8
-------------------
37
37
38
38
38
39
39
39
40
Event Recognition and Fault Rectification . . . . . . . . . . . . . . . . . . . . . . 9 --- 41

9.1
9.2
9.3
Alarms (machine shut ---down, red LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41

Warning Messages (yellow LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
Miscellaneous events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.1
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.3.1
10.3.2
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.10.1
10.10.2
10.11
10.12
10.13
10.14
10.15
10.15.1
10.15.2
10.15.3
10.16
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting maintenance interval counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cooling (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat maintenance (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Heat Recovery Maintenance (option W2 / W3) . . . . . . . . . . . . . . . . . . .
Air Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat maintenance (control cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting the Machine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Topping up the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Safety Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
-------------------------------------------------------
51
52
52
53
54
54
55
55
55
56
57
58
59
59
60
61
61
62
64
67
68
68
70
70
70
71
73
11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 74

11.1
Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 74
iii
Contents
Chapter --- page
11.2
11.3
11.4
11.5
Ordering Maintenance Parts and Operating Materials . . . . . . . . . . . . . . . . . . . .

Maintenance Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Parts for Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
11
---------
74
74
74
74
12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . 12 --- 81

12.1
12.2
12.3
12.4
12.5
De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
12
-----------
81
81
81
82
82
13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 84
13.1
13.2
13.2.1
13.2.2
13.2.3
13.2.4
Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipeline and instrument flow diagram (P&I diagrams) . . . . . . . . . . . . . . . . . . . .
Pipeline and instrument flow diagram (option C1) . . . . . . . . . . . . . . . . . . . . . . .
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
13
13
-------------
84
84
84
90
96
99
iv
Directory of Illustrations
Chapter --- page
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
Three---phase star (wye); four wire; earthed neutral . . . . . . . . . . . . . . . . . . . . . . .

Three---phase star (wye); three wire; earthed neutral . . . . . . . . . . . . . . . . . . . . . .
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air ---cooled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer and condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation recommendation, dimensions [in] . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive motor terminal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan motor terminal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control cabinet: overload protection relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control cabinet: motor protection switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control cabinet: control transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate drainage, dimensions [in] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet valve oil filling port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching off in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . . . .
Cleaning the cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilator grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Cooling Oil, Oil Separator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport by fork truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport by lifting cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 --- 7
2 --- 7
4 --- 16
4 --- 17
4 --- 18
4 --- 19
4 --- 19
4 --- 19
4 --- 22
4 --- 23
5 --- 24
6 --- 26
6 --- 27
6 --- 28
6 --- 28
6 --- 29
6 --- 30
6 --- 30
6 --- 31
6 --- 32
7 --- 34
7 --- 35
8 --- 37
8 --- 38
8 --- 39
10 --- 55
10 --- 56
10 --- 57
10 --- 58
10 --- 59
10 --- 61
10 --- 62
10 --- 63
10 --- 64
10 --- 66
10 --- 67
10 --- 69
10 --- 70
10 --- 71
10 --- 72
12 --- 82
12 --- 82
Table Directory
Chapter --- page
Tab. 1
Tab. 2
Tab. 3
Tab. 4
Tab. 5
Tab. 6
Tab. 7
Tab. 8
Tab. 9
Tab. 10
Tab. 11
Tab. 12
Tab. 13
Tab. 14
Tab. 15
Tab. 16
Tab. 17
Tab. 18
Tab. 19
Tab. 20
Tab. 21
Tab. 22
Tab. 23
Tab. 24
Tab. 25
Tab. 26
Tab. 27
Tab. 28
Tab. 29
Tab. 30
Tab. 31
Tab. 32
Tab. 33
Tab. 34
Tab. 35
Tab. 35
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitiy at rated pressure [CFM FAD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan motor data (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply 230V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply 460V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Quality Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General specification of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow rate and heat available (option W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow rate and heat available (option W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer, compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer, refrigeration system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload protection relay settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor protection switch settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist, installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil change intervals lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil change intervals speciality lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 --- 3
2 --- 3
2 --- 3
2 --- 4
2 --- 4
2 --- 4
2 --- 4
2 --- 5
2 --- 5
2 --- 5
2 --- 5
2 --- 7
2 --- 8
2 --- 8
2 --- 9
2 --- 9
2 --- 9
2 --- 9
2 --- 10
2 --- 10
2 --- 10
4 --- 23
4 --- 23
5 --- 25
6 --- 28
6 --- 29
7 --- 33
9 --- 45
9 --- 49
9 --- 50
10 --- 53
10 --- 54
10 --- 54
10 --- 54
10 --- 73
11 --- 74
vi
Regarding this Document

1
1.1
Handling the Document

The service manual is part of the machine.
Keep the service manual in a safe place throughout the life of the machine.
Pass the manual onto the next owner/user of the machine.
Ensure that all amendments are entered in the manual.
Enter details from the machine nameplate in the table in chapter 2 Technical Specifications.
1.2
Further Documents
Included with this Service Manual are documents intended to assist in safe and sure operation of the machine:

certificate of acceptance / operating instructions for the pressure vessel

manufacturers declaration or declaration of conformity in accordance with applicable
directives
SIGMA CONTROL Service Manual
Make sure all documents are at hand and their contents understood.
Request the supply of any missing documents from KAESER.

Make sure you give the data from the nameplate.
1.3
Copyright
This service manual is copyright protected. Inquiries regarding use or duplication of the
documentation should be referred to KAESER.
1.4
Symbols and Identifications
1.4.1
Warning notices
Here is a notice warning of danger.
DANGER
Here are consequences of ignoring the warning notice.

The word Danger indicates that death or severe injury can result from ignoring the notice.
Always read and diligently comply with warning notices.
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the danger symbol.
Signal word
DANGER
WARNING
CAUTION
Meaning
Warns of imminent threatening danger
Warns of possible threatening danger
Warns of a possibly
dangerous situation
Consequences of ignoring the warning

Death or severe injury or serious damage to
the machine is possible
Death or severe injury or serious damage to
the machine is possible
Light injury or slight damage possible
1 --- 1

1.4.2
Miscellaneous notices and symbols

Here is a task to be carried out.
This symbol identifies environmental protection measures.
This indicates important information.
1 --- 2
Technical Specification
2
Model and important technical information is to be found on the machine nameplate. The
nameplate is found inside the machine. It is fixed to the outside of the control cabinet.
Please transfer data from the nameplate.
Model
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQIPMENT
NUMBER
Tab. 1
Nameplate
A summary of the included options helps to relate the service manual information to your
machine.
Please enter details of options.
Code
K1
K3
H1
W1
W2
W3
C1
C2
T2
Option
Air cooled
Fillter mat panels
Machine mountings
Prepared for heat recovery
Internal heat recovery T= 25K
Internal heat recovery T= 55K
Modulation control
Optional filter monitoring package
Transformer power supply for refrigeration
dryer
Tab. 2
Options
2.1
Existing
Weight
Maximum weights are shown. Actual weights of individual machines are dependent on
equipment fitted.
ASD 25
3640
Weight [lb]
Tab. 3
ASD 30
4040
ASD 40S
4080
ASD 40
4320
Weight
2 --- 3
2.2
Temperature
ASD 25
Minimum cut ---in tempera40
ture [ F]
Typical airend discharge
167 --- 200
temperature during operation [ F]
Max. airend discharge
230
temp. (automatic shut --down) [ F]
Tab. 4
Machine temperatures
2.3
ASD 30
40
ASD 40S
40
ASD 40
40
167 --- 200
167 --- 200
167 --- 200
230
230
230
ASD 30
3000
40 115
40 115
ASD 40S
3000
40 115
40 115
ASD 40
3000
40 115
40 115
Ambient Conditions
ASD 25
3000
40 115
40 115
Maximum elevation [ft]

Ambient temperature [ F]
Inlet air / cooling air temperature [ F]
Humidity of the inlet air at
100
100
100
88 F [%]
Humidity of the inlet air at
50
50
50
113 F [%]
* Higher elevation permissible only after consultation with the manufacturer
Tab. 5
Ambient Conditions
2.4
100
50
Pressure
See nameplate for maximum working pressure.
Maximum working pressure [psig]
ASD 30
155
230
230
ASD 40S
155
230
230
ASD 40
155
230
230
Rated pressure [psig]

ASD 25
ASD 30
110
115
135
125
115
134
145
93
114
175
92
113
190
73
91
217
72
90
Tab. 7
Capacitiy at rated pressure [CFM FAD]
ASD 40S
166
166
132
129
112
110
ASD 40
191
191
163
159
127
125
Tab. 6
2.5
Blow--- off setting of the safety relief valve [psig]
ASD 25
125
155
175
230
217
230
Safety relief valve setting
Free air delivery (FAD)
2 --- 4
2.6
Sound Level
Operational state
under load at rated speed, rated delivery and rated pressure.
Measuring conditions:
Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance
ASD 25
Sound level [dB(A)]
66
Tab. 8
Sound Pressure Level
2.7
Motor and Performance
2.7.1
Compressor motor:
ASD 25
Rated power [HP]
25
Enclosure type
TEFC
Tab. 9
Compressor motor data
ASD 30
67
ASD 40S
67
ASD 40
69
ASD 30
30
TEFC
ASD 40S
40
TEFC
ASD 40
40
TEFC
ASD 30
3545
3545
1780
ASD 40S
3550
3550
3550
ASD 40
3550
3550
3550
ASD 30
0,75
1080
TEFC
ASD 40S
0,75
1080
TEFC
ASD 40
0,75
1080
TEFC
Rated speed [rpm]

ASD 25
Working pressure [psig]
125
3550
175
1780
217
1780
Tab. 10
Compressor motor rated speed
2.7.2
Fan Motor
Air cooling (option K1)
ASD 25
Rated power [HP]
0,75
]
Rated speed [rpm
1080
Enclosure type
TEFC
Tab. 11
Fan motor data (option K1)
2.8
Cooling oil
Ordering: see Spare Parts, Operating Materials, Service chapter 11.
Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can
form in compressor oils. These deposits block the flow of lubricant and cause excessive
wear and failure of moving parts. Contamination of the lubricant can allow the formation of
acids, causing extensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors does much more than lubricate. During the compression
process, it acts as a sealant in the airend which is important for maximum efficiency. The
lubricant also absorbs much of the heat of compression to cool the airend and reduce the
2 --- 5
temperature of the compressed air. Its not enough that a compressor cooling oil lubricates
well, it must stand up to the heat, pressure and contaminants that are present in every air
compressor.
2.8.1
General Information
KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire---resistant fluid. It has a flash point above 460 F. Since the user has total control over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
Regardless of the lubricant selected, the KAESER Sigma lubricants will separate readily
from water. If condensate occurs it can easily be removed. Let the compressor sit so that
any water can drain back to the separator tank and separate to the bottom. See chapter 10.11 proper draining procedure.
KAESER has several lubricants available that are specially formulated to match these demands. They feature excellent lubricity, outstanding demulsibility (ability to separate from
water), and long life.
M --- SERIES SEMI --- SYNTHETIC LUBRICANTS
M---Series SIGMA compressor cooling oils are the highest quality petroleum lubricants.
M---460 is specially blended to provide reliable performance in KAESER screw compressors.
S--- SERIES SYNTHETIC LUBRICANTS
S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. These synthetic lubricants begin as high quality petroleum feed stock.
They are then refined, processed and purified into fluids with very consistent molecular
structure. These oils are carefully blended to produce extremely consistant lubricants
with superior properties. SIGMA synthetic lubricants feature all the advantages of both
PAO and diester fluids.
S---460 lubricant is recommended for compressors operating in ambient temperatures
between 40 F and 105 F.
Specialty KAESER LUBRICANTS
S---680 lubricant may be used when ambient temperatures are always between 70 F
and 105 F.
FG---460 synthetic hydrocarbon based food grade lubricant is designed for use in
rotary screw compressors in the application where incidental food contact may occur
with the discharge air. This lubricant meets the requirements of the FDA Regulation 21
CFR 178.3570 and is USDA H ---1 approved and NSF certified. FG---460 is approved
for canning, food packing, meat and poultry processing and other applications where
incidental food contact may occur.
2.8.2
Cooling Oil Volumes

ASD 25
4.2
0.5
ASD 30
4.2
0.5
ASD 40S
4.2
0.5
Total charge [gal]

Top ---up volume [gal]
(minimum --- maximum
* Input the additional volume corresponding to your heat recovery system.
ASD 40
4.2
0.5
2 --- 6
ASD 25
0.3
ASD 30
0.5
ASD 40S
0.5
Additional volume [gal]

(option W2)
0.3
0.5
0.5
(option W3)
(option W1) *
* Input the additional volume corresponding to your heat recovery system.
Tab. 12
Cooling oil volumes
2.9
ASD 40
0.5
0.5
Electrical Connections
See electrical diagrams in chapter 13.2.4.
2.9.1
Power supply
The machine is designed for an electrical supply according to National Electric Code
(NEC) NEC---670, particulary NFPA 79, section 5.7. In the absence of any user ---specified
alternatives, the limits given in these standards must be adhered to. Consult manufacturer
for any other specific power supply.
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on power supplies like, for example, a three---phase (open) delta or three---phase star
with non ---earthed neutral.
Fig. 1
Three ---phase star (wye); four wire; earthed neutral
Fig. 2
Three ---phase star (wye); three wire; earthed neutral
The machine requires a symmetrical three---phase power supply transformer with a WYE
configuration output as shown in Fig. 1 and Fig. 2.
In a symmetrical three phase supply the phase angles and voltages are all the same.
Other power supplies are not suitable. Please contact KAESERs Application Engineering
department for options.
2.9.2
Power supply specifications

The following multi---strand copper core wires are given according to 2002 NEC 310 ---15,
Table 310 ---16 for 40 C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should
be checked and adjusted according to 2002 NEC 110 ---14 , 220 ---3,310 ---15, Table
310 ---16, 430 ---6, 430 ---22, 430 ---24 and other local codes.
Dual element time delay fuses are selected according to 2002 NEC 240 ---6,430 ---52 and
tables 430 ---52, 430 ---148 and 430 ---150.
2 --- 7
We strongly suggest using a separate copper conductor for the equipment GROUNDING.
NEC Table 250.122 will point out the minimum size, however, we recommend a ground
conductor the same size as the power leads, if local codes allow.
Electrical connections vary in some cases according to the maximum working pressure [psig] of the machine. These are shown in brackets ( ).
Rated power supply 230V 10%, 3 --- ph, 60Hz
ASD 25
Pre---fuse [A]
90 (125)
110
Supply
4xAWG1
(125)
4xAWG1/0
Consumption [A]
66 (125)
75
* Nominal cable temperature 75 C
Tab. 13
Supply 230V/3/60Hz
ASD 30
125
ASD 40S
125
ASD 40
150
4xAWG1*
4xAWG1/0*
4xAWG2/0*
85
98
112
ASD 30
60
4xAWG4
ASD 40S
70
4xAWG3
ASD 40
80
4xAWG2
44
49
56
Rated power supply 460V 10%, 3 --- ph, 60Hz

ASD 25
50
4xAWG6
(125)
4xAWG4
Consumption [A]
34 (125)
38
Tab. 14
Supply 460V/3/60Hz
Pre---fuse [A]
Supply
2.10
Internal Heat Recovery (option W2 / W3)

A soldered, plate heat exchanger is installed for heat recovery.
Generally water is used as the heat transfer medium. This must conform to the specification given below.
The manufacturer should be consulted before another type of heat transfer
medium is used.
Water Quality Specification
pH value
Hardness [ dH]
Chloride (Cl)* [mg/l]
Free chlorine gas (Cl2) [mg/l]
Sulphate (SO3) [mg/l]
Dissolved iron (Fe) [mg/l]
Hydrogen carbonate (HCO3) [mg/l]
Sulphate (SO4) [mg/l]
HCO3 / SO4
Electrical conductivity [ S/cm]
Ammonia (NH3) [mg/l]
7.5 to 9
4.0 ---8.5
< 150
< 1
< 1
< 0.2
70 ---300
< 70
> 1
10 ---500
< 2
2 --- 8
Dissolved magnesium (Mn) [mg/l]
Dissolved aluminium (Al) [mg/l]
Nitrate (NO3), dissolved [mg/l]
Hydrogen sulphate (SO2) [mg/l]
Free aggressive carbon dioxide (CO2) [mg/l]
Glycol [%]
Solids (particle size) [mm]
Algae
Tab. 15
Water Quality Specification
< 0.1
< 0.2
< 100
< 0.05
< 5
< 50
< 0.1
not allowed
If the heat transfer medium outlet temperature is to be kept constant, the

user must install an appropriate regulating device.
Heat Exchanger Specification
ASD 25
145
ASD 30
145
Maximum working pressure of the heat transfer

medium [psig]
Pressure drop [psig]
< 7
< 7
Plate material
1.4401
1.4401
Solder
Cu
Cu
Maximum permissible
210
210
temperature of the heat
transfer medium [ F]
Tab. 16
General specification of the heat exchanger
ASD 40S
145
ASD 40
145
< 7
1.4401
Cu
210
< 7
1.4401
Cu
210
Flow rate and heat capacity by heating from 110 F to 160 F (equivalent to T= 25 K),
(option W2)
ASD 25
2.42
16.0
ASD 30
2.95
19.5
Flow rate [gpm]

Max. heat capacity available [kW]
Max. heat capacity avail58
70
able [MJ/h]
16767
able [kcal/h]
Tab. 17
Flow rate and heat available (option W2)
ASD 40S
3.65
23.9
ASD 40
4.53
27.6
86
99
20550
23732
Flow rate and heat capacity by heating from 60 F to 160 F (equivalent to T= 55 K),
(option W3)
ASD 25
1.10
16.0
ASD 30
1.36
19.5
Flow rate [gpm]

Max. heat capacity available [kW]
70
able [MJ/h]
16767
able [kcal/h]
Tab. 18
Flow rate and heat available (option W3)
ASD 40S
1.67
23.9
ASD 40
1.89
27.6
86
99
20550
23732
2 --- 9
2.11
Refrigeration Dryer
Model
ASD 25
ASD 30
ASD 40S
ASD 40
Model *
* Transfer data from dryer nameplate to the table
Tab. 19
Refrigeration dryer model
Compressed Air System
Pressure drop [psig]
ABT 37
3
ABT 47
3
ABT 57
3
230
230
ABT 47
R 134a
3.1
305
ABT 57
R 134a
2.4
305
305
305
110
110
100
100
(in relation to 100 psig working pressure)
Maximum permitted working pres230

sure [psig]
Tab. 20
Refrigeration dryer, compressed air system
Refrigeration System
ABT 37
Refrigerant
R 134a
Maximum charge [lb]
2.2
Maximum permitted working pres305
sure [psig]
Safety pressure switch set point
305
[psig]
Fan pressure switch cut ---in setting
110
[psig]
Fan pressure switch cut ---out setting
100
[psig]
Tab. 21
Refrigeration dryer, refrigeration system
2 --- 10
Safety and Responsibility

3

Disregarding this notice can result in serious injury!
The machine is made to the latest technical safety standards and acknowledged safety
regulations. Nevertheless, risk of injury and death for the user and third parties and damage to the machine and other property can arise from its use.
The machine may only be used: when it is in technically perfect condition; for the purpose
for which it is intended; and when all safety measures as detailed in the service manual are
put into practice.
In particular, any faults relating to safety must be rectified immediately.
3.1
Correct Use
The machine is intended solely for industrial use in generating compressed air. Any other
use is considered incorrect. The manufacturer is not liable for any damages resulting from
such unspecified use or application. The responsibility, in this case, lies solely with the
user.
Correct use also includes compliance with the data contained in this manual.
The machine may only be used in consideration of the installation conditions.
3.2
Incorrect Use
Untreated compressed air may not be used:
as breathing air,
for any process in which the air can come into contact with food products.
3.3
Users Responsibilities
Personnel
Allow only specialists or persons who have been trained or instructed on this machine to
carry out work on the machine. This applies particularly for:
installation and initial start ---up,
maintenance and service work,
repairs,
inspections.
Allow work to be carried out on electrical equipment only by a qualified electrician or
trained personnel under the supervision of a qualified electrician, and according to electrical engineering regulations.
Ensure that all persons working on the machine have read, understood and observe the
safety ---relevant passages in the service manual.
Give clear instructions on reporting faults and damage to the machine.
Observe the relevant regulations during installation, operation, maintenance and repair of
the machine. These are, for example, valid national laws and safety and accident prevention regulations.
Adhere to inspection schedules and accident prevention regulations
The machine is subject to local inspection schedules.
3 --- 11
3.4
Safety Devices
Do not change, bypass or disable safety devices.
Do not remove or obliterate labels and notices.
Ensure that labels and notices are clearly legible.
More information on safety devices is contained in chapter 4 Design and Function, section 4.4 Safety Devices.
3.5
Hazards
Fundamentals: observe the accepted safety regulations
Observe safety regulations at all times when working on the machine.
Examples of these are requirements and national regulations concerning safety and accident prevention.
3.5.1
Danger from electric current

Electric shock can kill!
DANGER
Touching electrically energized components can cause serious injury or

death.
Isolate completely from the mains supply (all conductors)
(switch off at the main isolator)
Ensure the supply cannot be switched on again (lock off).
Check that no voltage is present.
Only work on electrical components when they are voltage---free.
Work carefully.
Before switching on again ensure that:

no one is working on the machine,

all panels are in place and secured,
all access doors are closed.
Work on the electrical equipment may only be carried out by a qualified electrician or by
instructed persons under the supervision of a qualified electrician.
Before the machine is switched on for the first time the user must provide and check measures to guard against electric shock by direct or indirect contact.
3.5.2
Danger from released spring force

Springs under tension or compression contain force. Uncontrolled release of this force can
cause serious injury or death.
WARNING
There is considerable danger of injury or death from the release of

spring force if spring--- loaded components are incorrectly opened (dismantled).
Minimum pressure/check valves, pressure relief valves and inlet valves are
under powerful spring loading.
Do not open (dismantle) valves.
3 --- 12

3.5.3
Danger from released compressed air

Compressed air is a contained force. Uncontrolled release of this force can cause serious
injury or death.
Severe injury or death can result from breathing compressed air.
DANGER
Injury and/or contamination can result from breathing compressed air.

Never breath untreated compressed air!
Air from this compressor must meet OSHA 29CFR1910.134 and
FDA 21CFR178.3570 standards, if used for breathing or food processing. Use proper compressed air treatment.
Food grade coolant must be used for food processing.
Compressed air can cause injury or death.
WARNING
Serious injury or death can result from loosening or opening components

under pressure.
Close shut ---off valves or otherwise isolate the machine from the air
main to ensure that no compressed air can flow back into the machine.
De---pressurize all pressurized components and enclosures.
Check all machine hose connectors with a hand ---held pressure gauge
to ensure that all read zero.
Extension or change to the compressed air supply system

If a compressed air installation is changed or a new machine installed, check the blow ---off
capacity of the safety relief valves on air receivers and pipelines.
Any safety relief valves of insufficient capacity must be replaced with larger models.
3.5.4
Further dangers
Handling cooling and lubricating fluids

Avoid contact with skin and eyes.

Do not inhale oil mist or vapor.
Do not eat or drink while handling cooling and lubricating fluids.
Fire, open flame and smoking are strictly forbidden.
Welding
When welding is taking place on or near the machine take adequate measures to ensure
that no parts of the machine or any oil vapors are ignited by sparks.
Spare parts
The use of unsuitable parts may adversely influence the safe operation of the machine.
Use only genuine KAESER spare parts for parts subject to pressure.
3.5.5
Refrigerant
Inhalation:
Remove the affected person to fresh air and keep them calm.
If breathing stops, apply artificial respiration and call for medical assistance.
3 --- 13

Skin contact:
Wash immediately with plenty of water. Seek medical attention.
Treat burns and frostbite.
Eye contact:
Rinse eye thoroughly with lukewarm water and seek medical assistance.
If required, request a copy of the safety data sheet dealing with the handling of refrigerants
for KAESER dryers.
3.6
Warning Symbols
Beware of life---threatening electrical voltage.
Do not touch electrical components; danger of electric shock.
Before opening, switch off at the main switch and lock off to secure against
unwanted or accidental switching on.
Warning of hot surface.
Do not touch surface --- danger of burning.
Wear long ---sleeve garments (not synthetics such as polyester) and protective gloves.
Beware --- machine starts automatically.
Machine can start automatically or by remote start command.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.
3.7
Emergencies
3.7.1
Fire supression
Suitable extinguishing media:

foam
powder
carbon dioxide
sand or earth
Unsuitable or unsafe extinguishing media:

3.7.2
powerful water jet
Cooling oil
Skin contact:
wash off immediately
Eye contact:
rinse thoroughly with lukewarm water and seek medical assistance.
If necessary, request a copy of the safety data sheet for KAESER lubricants.
3.7.3
Refrigerant
Inhalation:
Remove the affected person to fresh air and keep them calm.
If breathing stops, apply artificial respiration and call for medical assistance.
3 --- 14

Skin contact:
Wash immediately with plenty of water. Seek medical attention.
Treat burns and frostbite.
Eye contact:
Rinse eye thoroughly with lukewarm water and seek medical assistance.
If required, request a copy of the safety data sheet dealing with the handling of refrigerants
for KAESER dryers.
3.8
Environmental Protection
Do not allow cooling oil to escape to the environment or into the sewage system.
Store and dispose of used materials and replaced parts in accordance with local environment protection regulations. Observe national regulations. This applies particularly to parts
contaminated with cooling oil.
Do not allow refrigerant to escape into the atmosphere.
Give refrigerant only to authorized personnel for disposal.
3 --- 15
Design and Function

4
Design and Function
4.1
Machine Overview
4.1.1
Cabinet
Fig. 3
Cabinet
1 Control cabinet door

2 Latch
3 Removable panel
The cabinet, when closed, serves various purposes:
Sound damping
Protection
Cooling air flow control
Safe and reliable operation can only be ensured with the cabinet closed.
Latches are released by a key supplied with the machine.
Access doors are hinged to swing open, removable panels must be lifted off.
4.1.2
Function
Items in brackets [ ] correspond to the Pipe and Instrument Flow Diagram (P & I Diagram)
in chapter 13.2.1.
An air ---cooled machine serves to illustrate function.
4 --- 16
Design and Function
Fig. 4
1
2
3
4
5
Air ---cooled machine
Inlet valve [2]

Coupling [5]
Drive motor [3]
Oil filter [10]
Airend [4]
6
7
8
9
Control cabinet
Oil separator tank [6]
Air filter [1]
Oil/air cooler [11/13]
Add ---on cabinet for frequency converter /
refrigeration dryer
Compressor
Atmospheric air is cleaned as it is drawn in through the filter (8).
The air is then compressed in the airend (5).
The airend is driven by an electric motor (3).
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between
the rotors themselves and between them and the airend casing. The cooling effect directly
within the compression chamber ensures a low airend discharge temperature.
Cooling oil is recovered from the compressed air in the oil separator tank (7) and is then
cooled in the oil cooler (9). The oil then flows through the filter (4) and back to the point of
injection. Air pressure within the machine keeps the oil circulating and therefore a separate
pump is not necessary. A thermostatic valve maintains optimum oil temperature.
Compressed air, freed of its oil content in the separator tank (7), flows through the minimum pressure/check valve (8) into the aftercooler (9). The minimum pressure/check valve
ensures there is always sufficient air pressure to maintain cooling oil circulation.
The aftercooler brings down the compressed air temperature to 5 to 10 K above ambient.
Most of the moisture carried in the air is removed in the aftercooler.
4 --- 17
Design and Function

Refrigeration Dryer
Fig. 5
10
11
12
Refrigeration dryer and condensate drain

Refrigeration Dryer
Centrifugal separator
Condensate drain
The centrifugal separator (11) removes moisture from the air.

The downstream refrigeration dryer (10) removes the remaining moisture from the air.
The condensate drain (12) removes the condensate.
4 --- 18
Design and Function

4.2
Options
4.2.1
Machine mountings (option H1)

The machine mountings enable the machine to be anchored to the floor.
Fig. 6
4.2.2
Machine mountings
Filter mat panels (option K3)

Mats filter the cooling air and keep the cooler surface clean.
Fig. 7
1
4.2.3
Filter mat panel
Cooling air filter mat
Heat recovery
External heat recovery (option W1)
Connections are provided and bridged.
An external heat recovery system can be retro ---fitted at any time.
Internal heat recovery (option W2 / W3)
A plate heat exchanger (1) is installed for heat recovery.
Fig. 8
1
4.2.4
Internal heat recovery
Plate heat exchanger [26]
Optional filter monitoring set

Sensors monitor the operational condition of the filter. Indication is given as soon as maintenance is required.
4 --- 19
Design and Function

The following filters are monitored:
Air filter
Oil filter
Oil separator cartridge
4.3
Operating States and Control Modes
4.3.1
Operating states
There are three operating states:
LOAD: the inlet valve is open. The airend delivers compressed air to the system.
The drive motor runs under full load.
IDLING: The inlet valve is closed. The minimum pressure/check valve shuts off the oil
separator from the air system. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the
airend and back to the inlet valve via the venting valve.
The drive motor runs without load and draws little current.
STANDSTILL: The inlet valve is closed. The minimum pressure/check valve shuts off
the oil separator from the air system. The oil separator tank is vented.
The drive motor is stopped.
PARTIAL LOAD (option C1): The proportional controller continuously varies the degree
of opening of the inlet valve, and thereby the delivery rate of the compressor, in response and in proportion to the air demand. The airend delivers compressed air to the
system.
The load and power consumption of the drive motor rises and falls with the air demand.
4.3.2
Controller Operation
Using the selected control mode, the controller switches the compressor between its various operational states in order to maintain system pressure between the set minimum and
maximum values.
According to the individual compressed air demand one of the various control modes available will provide the optimum duty cycle for the machine.
4.3.3
Control Modes
The following control modes are available:
DUAL
VARIO
QUADRO
DUAL
In the DUAL control mode, the compressor is switched back and forth between full load
and idle to maintain system pressure between the set minimum and maximum values.
When the maximum pressure is reached the machine switches to IDLING. When the preset
idling time has elapsed the machine is switched to STANDSTILL.
The shorter the idling time setting, the sooner and more frequently the motor is stopped.
VARIO
The VARIO control mode is an extension of DUAL control. The difference being that under
VARIO control the idling time is automatically adjusted corresponding to the increased or
decreased maximum switching frequency of the drive motor.
4 --- 20
Design and Function

QUADRO
In QUADRO control mode the machine switches from LOAD to IDLE during periods of high
air demand and directly from LOAD to STANDSTILL during periods of low air demand.
This mode of control requires two pre---set time periods: the running time and the idle/
standstill time. The shorter these time settings, the sooner and more frequently the motor is
stopped.
4.3.4
Modulating control (option C1)

The modulating control mode is an extension of DUAL control. The difference being that, in
this mode, the delivery of the compressor is steplessly varied within the control range of
the machine.
Increasing air demand
The machine operates between PARTIAL LOAD and LOAD.
Falling air demand
The machine operates between PARTIAL LOAD, IDLE RUNNING and STANDSTILL.
4.3.5
Refrigeration dryer control modes

The following control modes are available:
CONTINUOUS
TIMER
CONTINUOUS
In this mode the refrigeration dryer runs continuously, even if the compressor is shut down.
This mode of control is set up at the factory.
TIMER
The refrigeration dryer is time---controlled and is switched on and off when the compressor
is shut down. In this mode, the operating temperature is held within tight limits.
This control mode saves energy.
Which control mode is the most practical, and when?
4.4
Control mode
Advantage
Disadvantage
CONTINUOUS
Constant dew point
Higher power consumption

when the compressor is
shut down
TIMER
Lower power consumption

when the compressor is
shut down
Brief increase in dew point

when the compressor re--starts
Safety Devices
The following safety devices are provided and may not be changed:
EMERGENCY STOP button
The EMERGENCY STOP button shuts down the compressor immediately. The motor
remains still. The pressure system is vented.
Safety relief valve
The safety relief valve protects the system from excessive pressure. This is factory set.
Housing and covers for moving parts and electrical connections.
Protection from accidental contact.
4 --- 21
Design and Function

4.5
SIGMA CONTROL Keys and Indicators
Fig. 9
Symbol
SIGMA CONTROL keys
Item Description
1
Function
ON (I)
Switch the machine on.
OFF (0)
Programmed operating mode is active.

Switch the machine off.
Operating mode:
Clock
Operating mode:
Remote control
Switching clock ---control on and off.

The LED lights when the machine is under clock
control.
Switching remote control on and off.
The LED illuminates when the machine is under remote control.
Toggles the machine between LOAD and IDLE.
Operating mode:
LOAD / IDLE
Arrow key
Scrolls down menu.
Arrow key
Reduces a parameter value.

Scrolls menu up.
Escape
Increases a parameter value.

Returns to the next higher menu level.
Exits the edit mode without saving.
Return/enter/save
key
Returns to the main menu when held down at least

10 seconds.
Only affects the message in the third line of the display (12).
Returns to the selected submenu.
Saves and leaves the edit mode.
4 --- 22
Design and Function

Symbol
Item Description
10
11
Events and information key
Acknowledge (reset) key
Function
Displays the event memory.
Selection from every menu.
Returns together with esc key (8).
Acknowledges (re---sets) messages and resets the
event memory (if permitted).
Tab. 22
SIGMA CONTROL keys
Fig. 10
SIGMA CONTROL indicators
Symbol
Item Description
Function
12
Display
Alphanumeric display with 4 lines.
13
Alarm
Blinks red when an alarm occurs.
14
Communication
Lights continuously when acknowledged.

Lights red if communication via the Profibus is interrupted.
15
Service/warning
LED
16
Controller power
ON
17
LOAD
Lights green when the machine is in the operating

state LOAD
18
Operating mode
IDLE
Lights green when the machine is in the IDLE mode.
19
Tab. 23
Machine ON
Blinks yellow for:

--- maintenance work required
--- warning message
Lights green when the power supply to the controller
is switched on.
Blinks green if the manualLOAD/IDLING changeover

key (5) is used.
The machine is switched on.
SIGMA CONTROL indicators
4 --- 23
Installation and Operating Conditions

5
5.1
Ambient Conditions
There must be no open flames or sparks at the place of installation.
Any welding work carried out on the equipment must not cause a fire hazard through
flying sparks or excessive temperature.
The machine is not explosion ---proof.
Do not operate in areas in which specific requirements with regard to explosion
protection are applied.
Clean inlet air with no damaging contaminants.
Inlet air free of explosive or chemically unstable gas or vapor.
Ambient temperature must be acceptable and stable.
The airend discharge temperature must remain constant to prevent the build ---up of
condensate.
Suitable fire extinguishing material must be readily available.
5.2
Installation Conditions
5.2.1
Place of installation and space required

The floor must be level, firm and able to bear the weight of the equipment.
If installed outdoors, the equipment must be protected from cold temperature, direct
sunlight, dust and rain.
Fig. 11
A
B
Z
Installation recommendation, dimensions [in]
Exhaust fan
Exhaust air duct
Inlet air opening
5 --- 24

5.2.2
Ventilation
Values given are minimum guidelines.
If the inlet aperture is insufficient a dangerous vacuum can be created in
the compressor room.
Ensure that the volume of air flowing into the compressor room is at
least equivalent to that being removed from it by the compressor and
exhaust fan.
Make sure that the machine and exhaust fan can only operate when
the inlet aperture is actually open.
ASD 25
6.5
5297
Inlet opening [sq.ft.]

Forced ventilation with exhaust ventilator: Flow rate
[cfm] at 0.4 in wc
Exhaust air duct:
25 1/2x25 1/2
Dimensions [in]
Tab. 24
Overview of ventilation
ASD 30
7.5
5886
ASD 40S
8.6
7063
ASD 40
8.6
8240
25 1/2x25 1/2
25 1/2x25 1/2
25 1/2x25 1/2
Exhaust ducting
Consult the manufacturer on the design of the ducting, length, number of bends, etc.
Further information on exhaust air ducts can be found in chapter 13.2.3.
5.2.3
Operating in a compressed air system

When the machine is connected to an air system, the network operating pressure must not
exceed 230 psig.
Initial filling of a fully vented air system generally creates a very high rate of flow through air
treatment devices. These conditions are detrimental to correct air treatment. Air quality can
be degraded.
To ensure maintenance of desired air quality when filling a vented air main we recommend
the installation of an air main charging system.
Please contact KAESER for assistance in selecting and installing an air main charging system.
5 --- 25
Installation
6
Installation
6.1
Safety
Severe injury or death can result from compressed air.
DANGER
Injury and/or contamination can result from breathing compressed air.

Contamination of food can result from using untreated compressed air for
food processing.
Air from this machine must meet OSHA 29CFR1910.134 and
FDA 21CFR178.3570 standards, if used for breathing or food processing. Use proper compressed air treatment.
Food grade coolant must be used for food processing.
WARNING

Minimum pressure/check valves, safety relief valves and inlet valves are
All functioning parts are factory set.
Changes may not be made without permission from the manufacturer.
Installation may only be carried out by persons fully trained in the basic safety concepts of
compressed air engineering.
6.2
Report Transport Damage

Check the machine for visible and hidden transport damage.
Inform the carrier and the manufacturer of any damage in writing.
6.3
Install the Compressed Air Connection

Pre --- condition: air main completely vented.
Fig. 12
1
2
Compressed Air Connection
Axial compensator or flexible hose

Shut ---off valve
6 --- 26
Installation
Shut ---off valve (2) to be installed by the user in the connection line.
Make the compressed air connection with a flexible hose (1) or an axial compensator (1).
6.4
Electrical Connection
Main power supply and overcurrent protection must be installed by a qualified electrician in
accordance with NEC, OSHA, and any applicable local codes.
Use wire conductor dimensions and fuse ratings in accordance with local regulations.
Guide values are given in chapter 2.9.
The user must provide the machine with a lockable supply ---disconnecting device.
This could be, for example, a switch ---disconnector with fuses. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
Before initial start--- up
The control transformer in the control cabinet has connections for various supply voltages. Check that the correct connections are made for the supply voltage provided for
the machine. If necessary, re---connect the transformer using the 5% taps to match
the supply voltage.
Connect the machine to the mains power supply in accordance with the electrical diagram in chapter 13.2.4.
6.4.1
Changing main voltage connections

Equipment:
The required jumpers (also known as bridges or links) are provided in

the control cabinet.
Pre --- condition: Machine switched off.

Main disconnect locked out.
The standard machine is set up for 230V, 3 ---ph, 60 Hz but may be modified for 460V,
3 ---ph, 60Hz.
The following parts have to be considered for making the change:

Jumpers in the drive motor terminal box.

Jumpers in the fan motor terminal box.
Drive motor overload protection relay.
Fan motor protection switch.
Control transformer
Transformer for the refrigeration dryer (only if present).
Changing the jumpers in the drive motor terminal box

Example:
Fig. 13
Drive motor terminal box
Open the terminal box and change the jumpers as shown in the electrical diagram.
6 --- 27
Installation
Changing the jumpers in the fan motor terminal box.
Example:
Fig. 14
Fan motor terminal box
Open the terminal box and change the jumpers as shown in the electrical diagram.
Connecting the overload protection relay
Overload protection cut ---outs for both main voltages are already provided in the control
cabinet.
Presetting:
Some values are dependent on the machine working pressure [psig], which is shown in
brackets ( ).
ASD 25
ASD 30
38 (125)
50
44
460V, 3 ---ph, 60Hz [A]
19 (125)
25
22
Tab. 25
Overload protection relay settings.
230V, 3 ---ph, 60Hz [A]
ASD 40S
57
ASD 40
66
29
33
Example:
Fig. 15
1
2
Control cabinet: overload protection relays
Reserve overload protection relay factory setting for 460V

Connected overload protection relay factory setting for 230V
Open the control cabinet and remove the overload protection relay (2).
6 --- 28
Installation
Mount the reserve overload protection relay (1) on the motor starter ( ---K1M) and connect up.
Check the overload protection relay pre---settings.
Connecting the motor protection switch
Motor protection switches for both main voltages are already provided in the control cabinet.
Presetting:
ASD 25
230V, 3 ---ph, 60Hz [A]
3.3
460V, 3 ---ph, 60Hz [A]
1.7
Tab. 26
Motor protection switch settings.
ASD 30
3.3
1.7
ASD 40S
3.3
1.7
ASD 40
3.3
1.7
Example:
Fig. 16
1
2
Control cabinet: motor protection switch.
460V motor protection switch

230V motor protection switch
Open the control cabinet and connect the appropriate motor protection switch in accordance with the electrical diagram.
Check the motor protection switch pre---settings.
6 --- 29
Installation
Connect the control transformer.
Example:
Fig. 17
1
Control cabinet: control transformer
Control transformer
Open the control cabinet and connect the control transformer in accordance with the
electrical diagram.
Connecting the dryer control transformer (option T2) for models equipped with a refrigeration dryer only
Power for the refrigeration dryer (if one is present) is provided by the control transformer.
This is not required for 460V main.
Example:
Fig. 18
1
Transformer connection
Transformer terminals
Open the control cabinet and insert the jumpers in the terminal strip ---X31 in accordance with the electrical diagram.
6 --- 30
Installation
6.5
Condensate Drain Connection

A hose connection is provided for condensate drain. Condensate must drain freely.
Collect condensate in a suitable container and dispose of in accordance with environmental regulations.
Condensate drain connection
< 200
Fig. 19
1
2
Condensate drainage, dimensions [in]
Drain hose
Condensate collecting line
6.6
Options
6.6.1
Mounting (option H1)

If the machine is supplied with mountings, these can be used to anchor it to the floor. Details of the mounting holes are contained in the dimensional drawing in chapter 13.2.3.
Use appropriate bolts to anchor the machine.
6.6.2
Heat recovery system connection
6.6.2.1
Internal heat recovery (option W2, W3)

The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the
connection ports.
Use connecting lines of suitable material. Take into account the effect of electro ---chemical
reaction.
Keep the effect of pressure surge on the heat exchanger as low as possible.
Where pressure surges are unavoidable provide an expansion tank as a damper.
6 --- 31
Installation
Fig. 20
A
B
Heat recovery
Outlet
Inlet
10
12
17
Shut ---off valve

Connection port with stopper
Safety relief valve
The user is to provide the following fittings:

Dirt trap with max. 0.1 mm strainer mesh.
Shut ---off valves (10) and connection ports (12) for maintenance and venting.
Safety relief valve (17) on the inlet (B) prevents build ---up of excessive pressure.
Blowoff pressure and capacity are related to the users installation design.
Keep to the heat exchanger technical specification.
6.6.2.2
Connect the water lines to the fittings.
Open the shut ---off valve on the outlet (A).
Slowly open the inlet (B) shut ---off tap to gradually fill the heat exchanger with water.
Vent the lines.
External heat recovery system (option W1)

The dimensional drawing in chapter 13.2.3 gives the flow direction, size and position of the
connection ports.
Follow the manufacturers instructions on connecting the external heat exchanger.
6 --- 32
Initial Start--- up
7
Initial Start---up
7.1
Before Initial Start---up (or Recommissioning)

Only trained specialist may carry out the initial start ---up procedure.
Incorrect start ---up can cause damage to the machine.
Special measures on recommissioning after storage
Storage period longer
than
12 months
36 months
7.2
Action
Change the oil filter.
Change the oil separator cartridge.
Change the cooling oil.
Have the motor bearings checked by an authorized
KAESER service agent.
Have the overall technical condition checked by an authorized KAESER service agent.
Check Installation and Operating Conditions

Cover all points in the check list before starting the machine.
Check
All installation conditions meet?
Users lockable supply disconnecting device installed?
Is the power supply as specified on the nameplate?
Supply cable section and fuse rating adequate?
All electrical connections checked for tightness?
Shut ---off valve fitted to compressed air outlet?
Connection made to air main with hose or axial compensator?
8
Sufficient cooling oil in the oil separator tank?
(cooling oil indicator outside the red zone?)
9
Required quantity of cooling oil poured into the inlet port?
10
Motor protection relay set correctly with regard to the
power supply?
11
Operators fully aquainted with safety regulations?
12
Machine anchored to the floor?
(option H1)
13
All access doors closed and latched and all removable
panels in place and secured?
Tab. 27
Checklist, installation conditions
1
2
3
4
5
6
7
7.3
Chapter
5
6.4
2
2.9.2
Done?
6.3
6.3
7.5
7.4
6.6.1
4.1.1
Setting the overload protection cut---out

Compressor motor
In the star ---delta configuration the phase current is fed via the overload protection cut --out. This phase current is 0.58 times the rated motor current (see motor nameplate).
7 --- 33
Initial Start--- up
Setting
The standard setting is made at the factory.
To prevent the overload protection cutout from being triggered by voltage fluctuations, temperature influences or component tolerances, the setting can be up to 15% higher than the
arithmetical phase current.
7.4
Motor Protection Switch Setting

Fan motor
In direct on ---line start the starting current is fed via the motor overload protection switch.
Setting
The standard setting is made at the factory.
To prevent the overload protection switch from being triggered by voltage fluctuations, temperature influences or component tolerances, the setting can be higher than the motor
rated current (see motor nameplate). It should be 1.2 x FLA.
7.5
Pour Cooling Oil into the Inlet Port

Equipment:
1 quart cooling oil
Pre --- condition: Machine switched off

Mains isolator locked off
The airend must be manually filled with cooling oil before initial start ---up and after being
out of use for more than 3 months.
Use the same type of oil.
A sticker giving the type of oil used is found near the oil separator tank filling port.
Fig. 21
1
2
Inlet valve oil filling port
Screw plug
Inlet valve
Remove the plug (1) from the inlet valve (2).
Pour cooling oil into the airend.
7 --- 34
Initial Start--- up
Fig. 22
1
2
Coupling
Compressor block
Coupling
Remove the cover (3).
3
4
Cover
Rotational direction arrow
Note the rotational direction arrow (4).

Grasp the coupling (2) and turn it and the airend shaft (1).
Replace the coupling cover (3).
7.6
Checking Direction of Rotation

The machine is designed for a clockwise field.
Check the supply with a phase sequence indicator.
If the compressor motor turns in the wrong direction, change the motor supply phases
L1 and L2.
Alternatively, the direction of rotation can be checked by briefly switching
the machine on and off again.
Switch the machine off as soon as the direction of rotation is seen
and compare it with the direction arrows on the motor and airend.
7.7
Initial Start---up
Open the shut ---off valve to the air network.
Switch on at the main supply isolator.
The controller makes a self---test and the green LED Power ON lights.
Press the Operating state LOAD/IDLE key.
Press the ON key.
The green LED Machine ON lights.
Allow the machine to idle for at least one minute.
This ensures good distribution of cooling oil.
Press the Operating state LOAD/IDLE key.
The machine switches to the LOAD state and delivers compressed air.
Watch for any faults occurring in the first hour of operation.
After the first 50 operating hours carry out the following:
Check that all electrical connections are tight.
7 --- 35
Initial Start--- up
7.8
Setting System Pressure

Adjustment is possible to suit individual operating conditions.
Network pressure setting is described in the SIGMA CONTROL service manual.
The machine may toggle a maximum of twice per minute between LOAD
and IDLE.
Reducing starting frequency:
Increase the difference between cut ---in and cut ---out pressure.
Add an air receiver downstream to increase buffer capacity.
7 --- 36
Operation
8
Operation
Fig. 23
1
2
3
4
8.1
Switching On and Off
Machine ON LED (green)

ON key (I)
OFF key (0)
Clock key
5
6
7
8
13
Remote key
LOAD LED
IDLELED
Power ON LED (green)
LOAD / IDLE toggle key
Switching On and Off

Always switch the machine on and off with the ON and OFF keys.
The supply disconnecting device is installed by the user.
8.1.1
Switching on
Compressed air can cause serious injury!
WARNING
Serious injury possible.

Never direct compressed air at a person or animal!
Ensure that:


all panels are in place,
all access doors are closed,
no parts of the machine are colder than + 37 F.
Switch on at the main supply isolator.

The controller makes a self---test and the green LED Power ON (8) lights.
Press the ON key (2).
The green LED Machine ON lights (1).
The compressor motor runs, assuming the system pressure is lower than the cut ---out
pressure.
8.1.2
Automatic restart
Pre --- condition: System pressure is lower than cut ---out pressure.
Automatic restart is factory ---set.
The machine restarts automatically when power is resumed after a power cut.
8 --- 37
Operation
8.1.3
Switching Off
Press the LOAD/IDLE toggle key (13).
The machine switches to IDLE and the LED (7) blinks.
After running in idle for 20 seconds, press the OFF key (3).
The Machine ON LED goes out (1).
Switch off and lock out the main supply isolator.
8.2
Switching Off in an Emergency and Switching On Again
Fig. 24
9
Switching off in an emergency
EMERGENCY STOP button
Switching off
Press the EMERGENCY STOP button (9)
The EMERGENCY STOP remains latched in.
The machine pressure system is vented and the machine is prevented from re---starting.
Starting again
Pre --- condition: Fault rectified.
Turn the EMERGENCY STOP button in the direction of the arrow to unlatch it.
Press the Reset key (11).
8.3
Remote On and Off Switching

Pre --- condition: Connection to a remote control device.
Press the Remote key (5).
The LED in the corner of the key lights. The remote control device has control of the machine.
The machine can still be switched on and off by the ON and OFF keys (2 and 3) if required.
8 --- 38
Operation
Apply the remote warning label to the machine where it is plainly visible.
BEWARE! This machine is remotely controlled and can start at any
time.
Label the remote control device accordingly:
Before starting, make sure that no one is working on the machine and
it can be safely started.
8.4
Switching on and off with the Clock

Pre --- condition: Clock programmed
Press the Clock key (4).
The LED in the corner of the key lights. The integrated clock has control of the machine.
Apply the time---controlled warning label to the machine where it is plainly
visible.
BEWARE! This machine is clock --- controlled and can start at any time.
8.5
Acknowledging and Resetting Warning and Alarm Messages
Fig. 25
10
11
12
Acknowledging and Resetting Warning and Alarm Messages

Warning LED (yellow)
Alarm LED (red)
Acknowledge (reset) key
Alarm
An alarm shuts the machine down automatically. The red Alarm LED blinks (11).
Warning
The display shows a maintenance or warning message.
The yellow warning LED (10) blinks, for example, if a maintenance task is due.
8.5.1
Resetting alarm messages

Pre --- condition: Fault rectified.
8 --- 39
Operation
Press the Acknowledgement (reset) key (12).
The alarm LED (red) goes out (11).
The machine is now ready to start again.
8.5.2
Resetting warning messages

Pre --- condition: The cause of the warning eliminated.
Maintenance task completed.
Press the Acknowledgement (reset) key (12).
The warning LED (yellow) goes out (10).
8 --- 40
Event Recognition and Fault Rectification

9

Inform KAESER service if the event cannot be rectified by the action suggested.
Do not attempt rectifications other than those given in this manual.
The measures valid for your machine are dependant on the individual equipment.
There are three types of event:
Description
An event that triggers an alarm (with automatic
shut ---down)
An event that triggers a warning (no shut --down)
Miscellaneous events (faults)
9.1
Indicated by
Blinking red LED
see chapter
9.1
Blinking yellow LED
9.2
No indication
9.3
Alarms (machine shut---down, red LED blinking)

Message
Possible cause
Action
access doors
Door opened during

machine operation.
Maximum airend discharge temperature exceeded.
Close the door(s).
ADT
ADT dT/dt
Maximum airend discharge temperature rise rate exceeded.
airend rotation
The motor is turning

in the wrong direction.
Connection is broken between the
system pressure
transducer and analog input 1.
AI 1 open cct.
AI 2 open cct.
Short circuit to
earth.
Connection is broken between the internal pressure
transducer and analog input 2.
KAESER service
technician only
Ensure adequate
ventilation.
Ensure permitted
room temperature
not exceeded.
Clean the cooler.
Cooling air outlet too
near a wall
Check the cooling
oil level.
Check airend and
piping to airend.
Check the cooling
oil level.
Check oil circulation.
Changeover phase
lines L1 and L2.
Check line and connection.
Check the sensor.
Check the sensor.
Short circuit to
earth.
9 --- 41

Message
Possible cause
Action
AI 3 open cct.
No connection between the sensor

measuring airend discharge temperature and the analog
input 3.
No connection between the sensor
measuring motor
temperature and the
analog input 4.
There is no connection between the
sensor allocated to
analog input 5 and
the input itself.
AI 4 open cct.
KAESER service
technician only
Check the sensor.
Check the sensor.
Check the sensor.
Check the sensor.
The connection between the sensor

and the analog input
is shorted.
Replace defective
sensor.
Back pressure in the

oil separator tank
caused by poor venting.
Check venting line.
Check venting valve.
blowoff prot.
The blowoff pressure of the pressure

relief valve on the oil
separator tank has
been exceeded.

Open the shut ---off
valve in the venting
line.
condensate drain
Fault in condensate
drainage.
Cooling water pressure too low.
Check condensate
drainage.
Check cooling water
supply.
Check that cooling
water shut ---off valve
is fully open.
AI 5 open cct.
AI 6 open cct.
Short circuit to
earth.
There is no connection between the
sensor allocated to
an analog input and
the input itself.
Short circuit to
earth.
...
AI 8 open cct.
AI 1 short cct.
...
AI 8 short cct.
back pressure
coolingwater low
Check
minimum
pressure/check
valve.
Check the minimum
pressure/check
valve, the control
valve and the inlet
valve.
Check sensor, line
and connection.
9 --- 42

Message
Possible cause
Action
EMERGENCYSTOP
EMERGENCY STOP
button pressed.
Unlatch the pushbutton.

Rectify fault.
First fan motor shut

down because of
overload.
Second fan motor
shut down because
of overload.
Third fan motor shut
down because of
overload.
Fault in the high tension cell.
The mains contactor
does not drop out
despite an OFF
command.
Investigate cause.
ext. message 0
...
ext. message 5
Fan M2 I
Fan M3 I
Fan M4 I
HT cell
mains cont. off?
mains cont. on?
The mains contactor

does not pull in despite an ON command.
mains monitor
Fault in mains power

supply.
Machine model indistinct
model
KAESER service
technician only
Reset overload trip.

Investigate cause.
Investigate cause.
Check high tension
cell.
Check auxiliary contact block.
Check 115 V available for the contactor.
Check auxiliary contact block on K1M.
Check 115 V available for the contactor.
Have the mains power supply checked.
Re---enter model
name
Exchange controller
motor I
Drive motor shutdown because of

overload.
motor T
Drive motor overheated.
motor bearings
Drive motor bearings overheated.
neutral p ---switch
neutral T---switch

Check minimum
pressure/check
valve.
Investigate cause.
Ensure adequate
ventilation.
Install an extractor.
Clean the motor.
Grease the motor
bearings with the
greasing device.
Rectify fault
Rectify fault
Change motor bearings.
9 --- 43

Message
Possible cause
Action
no press. buildup
Machine produces
no compressed air.
Check for air leaks.
The setpoint pressure does not rise

above 3.5 bar for a
preset period.
O 0.6/A 0.7
Short circuit in the

line between output
O 0.6 or O 0.7 and a
consumer.
Short circuit in the
line between output
O 1.6 or O 1.7 and a
consumer.
No changeover to
load as long as the
minimum oil pressure is not reached.
O 1.6/A 1.7
oil p
PD temperature
PD temperature
Power supply
pRV
RD compr. p
Compressor outlet
temperature too low.
Compressor outlet
temperature too
high.
2. Power failure

relief valve on the oil
separator tank has
been exceeded.
Pressure switch on
the refrigerant
compressor activated.
Check the coupling /

V---belts.
KAESER service
technician only
Check the inlet
valve.
Check minimum
pressure/check
valve.
Compare the internal pressure indicated with the reading

shown on the oil separator tank pressure gauge.
Check the consumer.
Check the consumer.
Check oil circulation. Replace defective

switch.
Check pressure
switch, line and connection.
Check sensor, regulator.
Check the frequency
converter.
Check the fan motor. Check sensor, regulator.
Clean the cooler.
Check the frequency
Check the cooling
converter.
oil level.
Check power supply
voltage.
Check door interlock.
Replace the pressure relief valve.
Ensure adequate
ventilation.
Replace defective
sensor.
Clean the refrigerant

condenser.
Clean the cooler.
9 --- 44

Message
Possible cause
Action
RD compr. T
Refrigerant compressor overheating.
Clean the refrigerant

condenser.
KAESER service
technician only
Ensure adequate
ventilation.
Install an extractor.
Cleaning the cooler
RD compr. T
separator dp
separator T
SIGMA CONTROL T
softstart
start T
Refrigerant compressor too cold.

Oil separator cartridge clogged.
Maximum temperature on oil separator
tank outlet exceeded.
SIGMA controller
housing temperature
exceeded 160 F.
Fault in the soft start

system.
Air temperature at
the airend discharge
port too low.
Ambient temperature below + 37 .

V---belts broken
The V---belts broke
during machine operation.
VFD
Frequency converter
faulty.
Tab. 28
Alarm messages and actions
Check refrigeration
dryer.
Replace the oil separator cartridge.
Check the cutout
line.
Check the cutout on

the oil separator
tank outlet.
Ensure adequate
ventilation.
Ensure permitted
room temperature
not exceeded.
Check control cabinet ventilator (filter
mats).
Heat the compressor room.
Check the soft start

system.
Install auxiliary heating.
Replace the
V---belts.
Check the frequency
converter.
9 --- 45

9.2
Warning Messages (yellow LED blinking)

Message
Possible cause
Action
access doors
Doors opened during machine operation.

The maximum permissible airend discharge temperature will soon be reached.
Close access doors.
ADT
air filter dp
air filter h
The pressure drop

across the air filter is
rising.
Bearing
maintenance h
blowoff prot.
Buffer battery
bus alarm
condensatedrain
elect. equip. h
ext.load signal?
Air filter element

clogged.
The service interval
to the next air filter
element check has
expired.
to the next bearing
greasing has expired.
Warning
relief valve will soon
be reached.
Data---retention battery run down.

The bus link from
the Profibus DP interface is interrupted.
Fault in condensate
drainage.
for checking electrical equipment and
wiring has expired.
External load signal
indistinct:
Increased cut ---out
pressure exceeded.
The external load
control has not
switched to idle.
KAESER service
technician only
Ensure adequate
ventilation.
Clean the cooler.
Cooling air outlet too
near a wall.
Check the cooling
oil level.
Replace the oil filter.
Clean/replace the air
filter element.
Clean/replace the air

filter element.
Grease the motor

bearings.

line.
Check link and plug.
Check condensate
drain and lines.
Reset the service interval counter.
Check settings of
the external controller.
Take the pressure
drops across filters
and dryer into account.
Check the minimum

pressure/check
valve, the control
valve and the inlet
valve.
Check the pressure
transducer.
Contact
KAESER service.
Check the interface
configuration.
Check electrical
components.
Check discrepancies between pressure transducers.
9 --- 46

Message
Possible cause
Action
error: RS 485
Wrong configuration
or transmission error.
Check the link/interface connections

between the two
controllers.
Bit rate and character frame for both

subscribers identical.
ext. message 0
...
ext. message 5
flash memory
Internal controller
memory error.
1. power failure:
Machine was re--started automatically.
mains voltage
modem problem
SIGMA CONTROL
does not recognize
the modem.
motor T
Drive motor overheating.
motor bearings h
motorstarts /h
motor starts /d
neutral p ---switch

to the next motor
bearing change has
expired.
The permissible
number of motor
starts was exceeded
in the last 60 minutes.
The permissible
number of motor
starts was exceeded
in the last 24 hours.
KAESER service
technician only
Check maximum
cable length and
screening.
Check interface parameters.
1 master and 1 slave
configured.
Rectify fault.
Exchange the controller.

Check power supply
voltage.
Check door interlock.
Check the link between the
SIGMA controller
and the modem.
Ensure adequate
ventilation.
Install an echaust
ventilator.
Clean the motor.
Change motor bearings.
Extend the idle period.

Increase capacity of
air receiver.
Increase cross---section of piping between compressor
and air receiver.
Extend the idle period.
Increase capacity of
air receiver.
Increase cross---section of piping between compressor
and air receiver.
Rectify fault
Check pressure
transducer.
Replace defective
sensor.
Check pressure
transducer.
Replace defective
sensor.
9 --- 47

Message
neutral T---switch
no press. buildup
oil change h
oil filter dp
oil filter h
oillevel
oil T
Possible cause
The compressor
cannot build ---up
pressure.

to the next oil
change has expired.
Oil filter clogged.
to the next oil filter
check has expired.
Oil level too low.
Cooling oil temperature too low.
Action
Rectify fault
Check the value given in the analog
data menu with the
reading on the oil
separator tank pressure gauge.
Change the cooling
oil.
Top up the cooling

oil.
Increase room temperature.
Warning
Compressor outlet
temperature is low.
Clean the cooler.
Check the cooling
oil level.
Remaining oil content
Warning
The purest class oil
content limit will
soon be reached.
Remaining oil
content
The purest class oil

content limit is exceeded.
separator dp
Check the scavenge

tube in the oil separator tank.
Check the dirt trap
strainer in the scavenge line.
Check the scavenge
tube in the oil separator tank.
Check the dirt trap
strainer in the scavenge line.
RAM
Replace defective
switch.
Install auxiliary heating.
Check sensor, regulator.
Warning
Compressor discharge temperature too high.
Internal RAM defective.
PD temperature
Check the minimum

pressure/check
valve, the control
valve and the inlet
valve.

Check the oil circuit.

Check temperature
gauge switch, line
and connection.
PD temperature
KAESER service
technician only
Check the frequency

converter.
Check the fan motor.
Check controller.
Exchange the controller.
Check the oil separator cartridge.
Check oil sensor line
and connection.
Check the oil separator cartridge.

Check oil sensor line
and connection.
9 --- 48

Message
Possible cause
Action
separator h

to the next oil separator cartridge check
has expired.
The set output test
function is activated.
System pressure
has fallen below the
set low value.
set output
System pressure
Air consumption too

high.
System pressure
(vacuum machines
only)
System pressure
has fallen below the
set high value.
VFD mains
Failure of power
supply to the frequency converter.
V---belt tension too
low.
to the next V---belt
re---tensioning has
expired.
V---belt tension
V---belt tens. h
Tab. 29
9.3
End the set output

mode.
Check air demand.
Check systpress.
low setting.
Check syspress.
high setting.
Check if the machine switches to
LOAD.
Check power
supply.
KAESER service
technician only
Check pressure
transducer.
Replace defective
sensor.
Re---tension the
V---belts.
Re---tension the
V---belts.
Warning messages and actions

Alarm
Possible cause
Action
Motor overload protection relay tripped

out.
Overload relay is defective or incorrectly

set.
Check setting.
The pressure system does not vent.
Motor defective; bearing damage or

windings shorted.
Airend defective.
KAESER service
technician only
Replace the overload relay.
Check pressure
drop across the separator cartridge.
Change the oil separator cartridge if necessary.
line.

Check minimum
pressure/check
valve.
Check the motor.
Check the airend.
9 --- 49

Alarm
Possible cause
Machine runs but

produces no compressed air.
Inlet valve not opening or only opening

partially.
Venting valve not
closing.
Pressure system lea- Check pipework and
king.
connections for leaks and tighten.
The air demand is
Check air network
greater than the cafor leaks.
pacity of the compShut down the conressor.
sumer(s).
Cooling oil runs out

of the air filter.
Hose coupling or
maintenance hose
still plugged into the
quick ---release
coupling on the oil
separator tank.
Oil level in the separator tank too high.
Compressor switches between load

and idle more than
twice per minute.
Inlet valve defective

Air receiver too
small.
Flow into the air network restricted.
Oil leaking into the

floor pan.
Hose coupling or
maintenance hose
still plugged into the
quick ---release
coupling on the oil
separator tank.
Oil cooler leaking
Connection leaking.
Cooling oil consumption too high.
Unsuitable oil used.

Oil separator cartridge split.
Oil level in the separator tank too high.
Tab. 30
Oil return line clogged.

Action
KAESER service
technician only
Check the valve.
Install auxiliary
compressor.
Remove coupling or
maintenance hose.
Drain off oil until the

correct level is reached.
Check the valve.
Install an air receiver
of sufficient capacity.
Increase air line diameters.
Check filter elements.
Remove coupling or
maintenance hose.
Replace the oil cooler.

Tighten connections.
Replace seals.
Use SIGMA FLUID
cooling oil.
Drain off oil until the
correct level is reached.
Check dirt trap in
the oil return line.
9 --- 50
Maintenance
10
Maintenance
10.1
Safety
Disregarding these notes and/or improper handling may result in serious injury.
Electric shock can kill!
DANGER
Touching electrically live components can cause serious injury or death.

Isolate completely from the mains supply (all conductors)
(switch off at the main isolator)
Ensure the supply cannot be switched on again (lock off).
Check that no voltage is present.
Only work on electrical components when they are voltage---free.
Work carefully.
Before switching on again ensure that:

WARNING

all panels are in place and secured,
all access doors are closed.

Minimum pressure/check valves, safety relief valves and inlet valves are
WARNING
Serious injury or death can result from loosening or opening components

under pressure.
Close shut ---off valves or otherwise isolate the machine from the air
system to ensure that no compressed air can flow back into the machine.
De---pressurize all pressurized components and enclosures.
Check all machine hose connectors with a hand ---held pressure gauge
to ensure that all read zero.
Machine damage from leakage
CAUTION
Leaks result in loss of oil and reduced performance.

Damage or complete breakdown can result.
Test run after maintenance or service.
Carry out a visual check of the machine.
10 --- 51
Maintenance
Maintenance work may only be carried out:
by persons trained in the machine and persons under the supervision of an expert,
by experts,
by an authorized KAESER service agent.
Work on electrical devices may only be carried out in accordance with electrical regulations:
by persons trained in the machine under the supervision of an
electrician,
by an electrician,
by an authorized KAESER service agent.
10.2
Maintenance Schedule
Maintenance intervals are recommendations only and should be adjusted
to suit the installation and operating conditions.
According to the way a machine is equipped, sensors and/or maintenance interval counters monitor the operational state of important functional devices. Necessary maintenance
tasks are signalled by the SIGMA controller.
Keep a log of all service work.
This enables the frequency of individual maintenance tasks to be compared with KAESERs recommendations. A list is given in chapter 10.16.
10.2.1
Resetting maintenance interval counters

Maintenance interval counters indicate the operating hours between maintenance tasks.
When a maintenance task is completed, reset the corresponding counter to its original
value.
See the SIGMA CONTROL service manual.
Pre --- condition: Maintenance task completed.
Service message reset.
Activate password level 4.
Select the appropriate entry from the maintenance menu.
Select reset and y and confirm with the enter key.
10 --- 52
Maintenance
10.2.2
Regular maintenance work

When operating conditions are unfavourable (e.g. dusty atmosphere) or
when the equipment is heavily utilized, maintenance tasks must be carried
out more frequently (shorter intervals).
Heed controller maintenance messages.
Have KAESER service adjust the maintenance interval counters to
suit operating conditions.
Interval
Weekly
Every 1000 h
Indicated by
SIGMA CONTROL
Indicated by
SIGMA CONTROL
but at least annually.
Indicated by
SIGMA CONTROL
but at least every
3 years.
Every 3000 h
variable (see
chapter
LEERER MERKER)
Annually
Maintenance tasks
Check cooling oil level.
Clean or renew the filter mats.
Oil and air cooler maintenance.
Heat recovery system maintenance.
Clean the refrigerant condenser.
Air filter maintenance.
see chapter
10.10.1
10.3.2 / 10.6
10.3
10.4
10.15.1
10.5
10.12
10.14
Check the coupling.

Change the cooling oil.
10.8
10.11
Check that all electrical connections are tight.

Check the pressure relief valve.
Check the oil and air coolers for leaks.
Cleaning the condensate drain
10.13
10.3
10.15.3
h = operating hours
Tab. 31
Regular maintenance work
10 --- 53
Maintenance
10.2.3
Cooling oil changing intervals

The duty cycle and ambient conditions are important criteria for the number and length of
the change intervals.
KAESER LUBRICANTS
SIGMA
DESCRIPTION
LUBRICANT
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
First Oil Change
Subsequent Oil
Change
M---460
ISO 46 Semi---Synthetic Lubricant
2000 Hours
3000 Hours
S---460
ISO 46 Synthetic Lubricant
6000 Hours
8000 Hours
* Cool to moderate ambient temperatures, low humidity, high duty cycle

Tab. 32
Oil change intervals lubricants

SPECIALTY KAESER LUBRICANTS
(Refer to product information to determine suitability.)
SIGMA
DESCRIPTION
LUBRICANT
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
First Oil Change
Subsequent Oil
Change
S---680
ISO 68 Synthetic Lubricant
6000 Hours
8000 Hours
FG---460
ISO 46 Food Grade Synthetic

Fluid
2000 Hours
3000 Hours
* Cool to moderate ambient temperatures, low humidity, high duty cycle

Tab. 33
10.2.4
Oil change intervals speciality lubricants
Regular service work

Only authorised KAESER service agents should carry out service work.
When operating conditions are unfavourable (e.g. dusty atmosphere) or
when the equipment is heavily utilised, service work must be carried out
more frequently (shorter intervals).
Interval
Maintenance tasks
Up to 12000 h
Check valves.
Up to 12000 h, at
Change the drive motor bearings.
the latest every
Change the fan motor bearings or the motor complete.
3 years
Up to 36000 h, at
Change the coupling.
the latest every
Change the hose lines.
8 years
Tab. 34
Regular service work
10 --- 54
Maintenance
10.3
Cooler Maintenance
10.3.1
Air cooling (option K1)

Equipment:
brush
vacuum cleaner

Machine cooled down.
Check the cooler regularly for contamination. Frequency is mainly dependant on local operating conditions.
Contamination causes overheating and machine damage.
Avoid dust disturbance. Wear breathing apparatus if necessary.

Do not use sharp objects to clean the cooler. The cooler could be damaged.
A severely contaminated cooler should be cleaned by a KAESER service agent.
Fig. 26
1
2
10.3.2
Cleaning the cooler
Cooler
Brush
Dry brush the cooler (1) and use a vacuum cleaner to suck up the dirt.
Filter mat maintenance (option K3)

Equipment:
Warm water and household detergent

Spare parts (as required)

10 --- 55
Maintenance
Fig. 27
1
2
3
Filter mat panel
Filter mat
Retaining frame
Fixing
Removal
Unlock the fixings (3).
Use a screwdriver to turn the fixing 90 anti---clockwise.
Remove the frame (2).
Cleaning
Beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary, wash the
mat in lukewarm water and household detergent then rinse thoroughly.
Replace the mat if cleaning is not possible or has already been carried out five times.
Replacing
Replace the frame and close the fixings.
Press and turn the fixings 90 clockwise until they latch.
10.4
Internal Heat Recovery Maintenance (option W2 / W3)

Deposits in the heat exchanger in machines with heat recovery systems can adversely affect heat transfer.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is
dependant on the characteristics of the heat transfer medium.
Contamination
Have an authorised KAESER service agent clean the heat exchanger as soon as a
pressure drop in the heat transfer medium is detected.
Leakage
If a leak occurs, cooling oil can flow into the heat transfer medium as pressure the cooling
oil circuit is generally higher.
Check the heat exchanger visually for leaks.
Have an authorized KAESER service agent check the heat exchanger for internal leaks
at least once a year.
10 --- 56
Maintenance
10.5
Air Filter Maintenance.

Equipment:
Compressed air for blowing out


Mains disconnect is locked out
Machine is cooled down.
Fig. 28
1
2
3
Air filter maintenance.
Nut
Nut
Rear side
4
5
Air filter cartridge

Cover
Open the air filter housing:

Unscrew the nut (1) securing the cover (5) and remove the filter insert.
Unscrew the nut (2) and remove the rear side (3).
Do not clean the air filter cartridge with liquids.
All sealing surfaces are matched to each other.
The use of unsuitable air filter cartridges can permit dirt to ingress into the
pressure system and cause damage to the machine.
Clean the air filter cartridge by tapping
Renew the air filter cartridge after two years at the latest or after it has been cleaned
five times.
Tap the cartridge at the end a number of times with the palm of the hand.
Cleaning the air filter cartridge with compressed air:
Use dry compressed air (< 70 psig!) to blow dirt from the air filter cartridge at a slant
from the inside to the outside.
10 --- 57
Maintenance
Close the air filter housing
Clean all parts and sealing surfaces.
Insert the air filter element (4) in the cover (5) and place on the rear side (3).
Secure the air filter housing with the screw and wing nut (2).
Insert the air filter housing in the side panel and secure the cover (5) with the wing
nut (1).
Close all access doors and replace all cover panels.
Switch on the power supply and reset the maintenance interval counter.
10.6
Filter mat maintenance (control cabinet)

Equipment:
Warm water and household detergent


Mains disconnect is locked out
Machine is cooled down.
Fig. 29
1
2
Ventilator grill
Ventilator grill
Filter mat
Removal
Remove the ventilator grill (1) and the filter mat (2).
Cleaning
Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat
in lukewarm water (40 C) and household detergent then rinse thoroughly.
Renew the mat if cleaning is not possible or has already been carried out five times.
Replacing
Lay the filter mat in the frame and push on the grill to latch.
10 --- 58
Maintenance
10.7
Electric Motor Maintenance

Compressor motor
The bearings of the compressor motor are permanently greased.
Fan motor
Fan motor bearings are permanently greased and need no further greasing.
10.8
Checking the Coupling

Danger of injury from rotating coupling!
WARNING
Severe injury could result from touching the coupling while it is rotating.
Never switch the machine on without the guard in place over the coupling.
The coupling must be carefully inspected at regular intervals.

A defective coupling is recognizable by:

noisy operation,
surface cracks,
color change.
Fig. 30
1
2
Checking the Coupling
Safety screen
Coupling
Check for uneven or noisy operation

Check the coupling (2) for noisy or uneven operation.
Check for damage
Remove the fixing screws from the safety screen (1).
Turn the coupling by hand and look for damage or color change.
Have a damaged coupling changed by an authorised KAESER service agent.
Refit the safety screen.
Close all access doors and replace all cover panels.
10 --- 59
Maintenance
10.9
Venting the Machine Manually


WARNING
Compressed air and devices under pressure can injure or cause death if
the contained energy of the air is released suddenly or uncontrolled.
After shutting down the compressor and venting the oil separator tank
there is still pressure on the check valve from the air main.
Close the shut ---off valve provided by the user to isolate the machine
from the air main.
Vent the oil separator tank.
Vent the air aftercooler to completely depressurize the system between
the users shut ---off valve and the minimum pressure/check valve.
Escaping oil mist is damaging to health.
CAUTION
Do not direct the maintenance hose at a person while venting.

Do not inhale oil mist or vapor.
Avoid contact with skin and eyes.
Before undertaking any maintenance or service work on the pressure system the machine
must be isolated from the air system and completely vented.
The machine is vented in three stages:

the oil circuit vents automatically when the machine is switched off,
air is vented manually from the oil separator tank,
air is vented manually from the air cooler.
Venting
Close the users shut ---off valve between the machine and the air main.
If no shut ---off valve is provided, the complete air system must be vented.
The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.
10 --- 60
Maintenance
Fig. 31
1
2
Ventilate the machine.
Hose coupling (air cooler venting)

Pressure gauge
6
7
Male hose coupling/fitting

Shut ---off valve
A: closed
B: open
Maintenance hose
Hose coupling (oil separator tank ven8

ting)
Check that the oil separator tank pressure gauge reads zero.
After automatic venting the pressure gauge does not read zero?
Make sure that the shut ---off valve is closed.
If manual venting does not bring the oil separator tank pressure gauge
to zero, call KAESER service.
Manually venting the oil separator tank
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (3).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
Manually venting the compressed air cooler
10.10
Checking and Topping up the Cooling Oil
10.10.1 Check cooling oil level.

Pre --- condition: Machine has been running at least five minutes under load.
(minimum 50 Hz for machines under frequency control).
Danger of burning from hot surfaces!
CAUTION
Skin burns are possible.

Wear long ---sleeve garments and protective gloves.
Work carefully.
10 --- 61
Maintenance
Fig. 32
2
3
4
5
Check cooling oil level.
Oil separator tank

Oil level indicator
Indicator markings
Green zone
Readout oil level.
min
OK
max
Minimum oil level

Oil level optimum
Oil level maximum
When the indicator shows minimum level, top up the oil.

10.10.2 Topping up the cooling oil
Equipment:
Cooling oil

Danger of explosion from oils and lubricants!

WARNING
Danger of explosion from oil mist and vapors.

Fire, open flame and smoking are forbidden!
Damage to the machine from unsuitable oil
CAUTION
Never mix different types of oil.

Top up only with the same type of oil as already in the machine.
Venting
If no shut ---off valve is provided, the complete air system must be vented.
The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.
10 --- 62
Maintenance
Fig. 33
1
2
3
Topping up the cooling oil

Pressure gauge
Hose coupling (oil separator tank venting)
5
6
7
Oil level indicator

Shut ---off valve
A: closed
B: open
Oil filling port with plug
8
Maintenance hose
Check that the oil separator tank pressure gauge (2) reads zero.
After automatic venting the pressure gauge does not read zero?
Make sure that the shut ---off valve is closed.
If manual venting does not bring the oil separator tank pressure gauge
to zero, call KAESER service.
Manually venting the oil separator tank

Manually venting the compressed air cooler
Topping up the cooling oil
Open the filler plug (4) slowly.
Top up the cooling oil.
Replace the plug gasket if necessary and re---insert the plug.
Start the machine and carry out a test run
Close all access doors; replace and secure all removable panels.
Open the users shut ---off valve between the machine and the air main.
Start the machine and allow it to idle for at least one minute. Then switch to LOAD.
After about five minutes, check the oil level and top up if necessary.
Carry out a visual check for leaks.
10 --- 63
Maintenance
10.11
Changing the Cooling Oil

Equipment:
Cooling oil
Have the oil container ready.
Thoroughly drain the oil from the separator tank, the cooler and the heat recovery system if
fitted.
Dispose of the used oil in accordance with local environment protection regulations.
Danger of burning from hot components and oil.
CAUTION
Wear long ---sleeve clothing and gloves.

Work carefully.
Fig. 34
Changing the Cooling Oil, Oil Separator Tank
1
2

Pressure gauge
6
7
Hose coupling (oil separator tank venting)

Oil filling port with plug
Oil level indicator

Shut ---off valve
A: closed
B: open
Maintenance hose
9
10
11
Hose coupling (oil drain)

Shut ---off valve (venting line)
Shut ---off valve (oil drain)
4
5
Compressed air helps to expel the oil.

This pressure can be generated by the machine itself.
Alternatively, an external source of compressed can be used.
External air is necessary when:

the machine is not operational

the machine is to be restarted after a long standstill period.
Oil changing with help from internal pressure

Pre --- condition: Machine has been running at least five minutes under LOAD.
Machine is switched off.
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
10 --- 64
Maintenance
Close the shut ---off valve (10) in the venting line.
Start the machine in idle and watch the oil separator tank pressure gauge (2) until it
reads 40 ---70 psig.
Switch the machine off.
Switch off and lock out the main supply isolator.
Wait at least two minutes for oil to flow back to the separator tank.
Alternative: Oil changing with help from an external pressure source
External source of compressed air available.
Close the shut ---off valve (10) in the venting line.
Connect the maintenance hose to an external air supply.
Open the shut ---off valve (7) until the pressure gauge on the oil separator tank reads
40 ---70 psig.
Close the shut ---off valve (7) and withdraw the hose fitting from the coupling.
Draining the oil from the separator tank
Contact KAESER service if condensate is detected in the oil.
It is necessary to adjust the airend discharge temperature to suit operating
conditions.
Place the end of the maintenance hose in the oil container and secure it in place.
Open the shut ---off valve (11).
Open the shut off valve (7) in the maintenance hose slowly and close when air escapes.
Close the shut ---off valve (11) and unplug the hose.
10 --- 65
Maintenance
Draining the oil from the cooler
Fig. 35
1
2
3
Changing the Cooling Oil
Oil cooler
Hose coupling (oil drain)
Shut ---off valve
6
7

Shut ---off valve

Place the end of the maintenance hose in the oil container and secure it in place.
Open the shut ---off valve (3).
Open the shut ---off valve (7) slowly and allow oil and air to drain completely.
Check that the oil separator tank pressure gauge reads zero.
Close the shut ---off valve (2) and unplug the hose.
Filling with cooling oil
Open filler plug (4, Fig. 34) slowly.
Fill with oil.
Machines with heat recovery systems need correspondingly more oil.
Check the plug and gasket for damage and re---insert the plug.
Allow the machine to idle for at least one minute. Then switch to LOAD.
10 --- 66
Maintenance
10.12
Oil filter maintenance

Equipment:
Spare parts

Danger of burning from hot components and oil.

CAUTION
Wear long ---sleeve clothing and gloves.

Work carefully.
Fig. 36
1
2
Changing the Oil Filter
Oil filter
Direction to unscrew
Dispose of parts and materials contaminated with oil in accordance
with local environment protection regulations.
Unscrew the oil filter counter ---clockwise, catch oil spillage and dispose of correctly.
Lightly oil the new oil filter gasket.
Screw on the new filter using hand pressure only. Do not use any tool.
The oil filter is turned clockwise to tighten.

10 --- 67
Maintenance
10.13
Checking the Safety Relief Valve.

Activate password level 4.
In order to check the pressure relief valve, the machines working pressure is raised above
the blowoff pressure of the valve.
There is danger of bursting if the permissible working pressure is exceeded.
WARNING
Noise from the pressure relief valve blowing off. Danger of scalding from
hot oil. Danger of injury from bursting components or the release of compressed air.
Wear ear and eye protection.
Work carefully.
Abort the test if the working pressure reaches 10% above the blowoff
pressure of the valve.
Carry out the test exactly as described in the SIGMA CONTROL manual.
Blowoff protection and system pressure monitoring are switched off during
the test.
The machine may only be operated with a correctly functioning safety relief
valve.
Observe the pressure indicator on the SIGMA controller and call up the test function.
Stop the test as soon as the safety relief valve blows off or working pressure reaches
10% above the blowoff set point.
Replace a defective safety relief valve.
Deactivate the test function.
10.14
Changing the Oil Separator Cartridge

Equipment:
Spare parts
Precision pressure gauge
Cleaning rags

The life of the oil separator cartridge is influenced by:

contamination in the air drawn into the compressor,

adherence to the schedule of oil and air filter changes,
10 --- 68
Maintenance
Fig. 37
14
15
16
17
Changing the Oil Separator Cartridge
Cover
Dirt trap
Air pipe
Retaining bolt
19
Pipe fitting
20
Fitting
21
Gasket
23
25
Minimum pressure/check valve
Unscrew the fitting (20) and carefully put the parts to one side; pull out the copper
pipe at item (15).
Unscrew the fittings (19) from the ends of the air pipe (16).
Withdraw the air pipe from the minimum pressure/check valve (25) and push carefully
to one side.
Remove the cover retaining bolts (17) and carefully lift the cover (14).
The oil separator element cannot be cleaned.
Dispose of parts and materials contaminated with oil in accordance

Take out the used oil separator element (23) together with the gaskets (21) and dispose of according to environmental regulations.
Wipe all sealing faces with a cleaning rag.
Insert the new oil separator cartridge with gaskets and re---fix the cover.
Renew the dirt trap (15) strainer and O ---ring.
Connect the air pipe to the minimum pressure/check valve.
Replace and tighten all fittings.
10 --- 69
Maintenance
10.15
Refrigeration Dryer
10.15.1 Cleaning the refrigerant condenser

Equipment:
Compressed air
vacuum cleaner

Fig. 38
6
7
8
Refrigerant condenser
Screws
Cover
Refrigerant condenser
Remove the screws (6) and take off the cover (7).
Use compressed air (< 70 psig) to blow the condenser (8) through from outside to
inside and then vacuum up the dirt.
Replace the cover.
10.15.2 Testing condensate drainage

Pre --- condition: Machine running
Hot components --- danger of burning

CAUTION
Wear long ---sleeve clothing.
Work carefully.
Condensate drains are found on the centrifugal separator and in the refrigeration dryer.
10 --- 70
Maintenance
Fig. 39
1
Testing condensate drain
TEST button
Press and hold the TEST button (1) for at least two seconds.
The condensate drain opens.

Condensate does not drain out?
The drain line (hose) at the back of the drain is blocked.
Switch the machine off and clean or replace the drain hose.
Repeat the test.
Condensate does not drain out?
Condensate drain blocked.
Clean the condensate drain as described in chapter 10.15.3.
10.15.3 Cleaning the condensate drain
Equipment:
Compressed air
Cleaning rags

10 --- 71
Maintenance
Fig. 40
1
2
3
4
5
6
Screw
Diaphragm
Screw
Diaphragm seat
Compression spring (diaphragm)
Diaphragm cover
7
8
9
10
11
Fitting
Compression spring (valve core)
Valve core
Housing
Cap
Removing the condensate drain

Close the shut ---off valve upstream of the condensate drain.
Unscrew the drain hose fitting (7).
Remove the securing screws (1) and remove the drain.
Unscrew the securing screws (3) and remove the diaphragm seat (4).
Take out and clean the compression springs (5 and 8), the diaphragm (2) and the
valve core (9).
Renew damaged or worn parts.
Blow out the casing with compressed air (< 70 psig).
Reassemble and check correct seating of spring and diaphragm.
Remounting the condensate drain
Reattach the drain to the shut ---off valve fitting.
Re---connect the drain hose fitting and open the shut ---off valve upstream of the drain.
10 --- 72
Maintenance
10.16
Logging Maintenance Work

Machine number:
Date
Tab. 35
Maintenance task carried out
Operating hours
Signature
Maintenance log
10 --- 73
Spares, Operating Materiels, Service

11
Spares, Operating Materials, Service
11.1
Note the nameplate

Take data from the nameplate for all enquiries and spare parts orders.
11.2
Ordering Maintenance Parts and Operating Materials

Personal injury or machine damage may result from the use of unsuitable spare parts or operating materials.
CAUTION
Unsuitable or poor quality maintenance parts and operating materials may
damage the machine or impair its proper function.
Damage to the machine can also result in personal injury.
Use only genuine spare parts and authorised operating materials.
Have an authorised KAESER service agent carry out regular maintenance.
KAESER maintenance parts and operating materials correspond to the original. These are
correct for use in our machines.
Compressor
Name
Air filter cartridge
Control cabinet filter mat
Filter mat (cooler)
Oil filter
Cooling oil
Tab. 36
Machine maintenance parts
11.3
Quantity
1
2
1
1
1
1
material number
1250
1100
1050
1200
1450
1600
Maintenance Contract
Sign a maintenance contract with an authorized KAESER service agent.
This ensures the utmost reliability and availability of your compressed air supply system.
11.4
Service Addresses
Address of KAESER agents are given at the end of this manual.
11.5
Spare Parts for Service and Repair

These spare parts lists are intended for trained personnel.
They contain important information for preventive service.
Service and repair work not described in the this manual should only be
carried out by a KAESER service workshop or one authorised by KAESER.
11 --- 74
De --- commissioning, Storage and Transport

12
De---commissioning, Storage and Transport
12.1
De ---commissioning
De---commissioning is necessary when:
the machine will not be needed for some time,
the machine is to be moved to another location,
the machine is no longer needed,
the machine is to be scrapped.
Temporarily out of service
Pre --- condition: The machine can be started at regular intervals.
Run the machine once a week under load for at least 30 minutes to ensure corrosion
protection.
Out of service for a considerable period

Pre --- condition: When running for the last time before taking out of service the machine
should have run under load for at least 30 minutes.
Machine switched off and fully vented.
Main supply isolator switched off and locked.
12.2
Allow the machine to cool down completely.
In water ---cooled machines, disconnect the water supply and drain all water from the
machine.
Disconnect all air and electrical connections.
Packing
Equipment:
Desiccant
Plastic sheeting
Wooden transport crate
Pre --- condition: Machine is de---commissioned.

Machine dry and cool.
Place desiccant inside the machine cabinet.
Wrap the machine in plastic sheeting.
Transport packing
A wooden crate is required for ground transportation to protect the machine from mechanical damage.
Consult an authorized KAESER service agent for advice on packing for sea or air transport.
12.3
Storage
Pre --- condition: The machine is adequately packed.
Store the machine in a dry, frost ---free room.
Prevent entry of moisture and condensation.
12 --- 81

12.4
Transporting
Use only a fork truck or lifting cradle.
Take weight and centre of gravity into consideration. The centre of gravity is shown in the
drawing in chapter 13.2.3.
The water cooling system of water ---cooled machines must be drained
completely if there is danger of frost.
Fork truck
Pre --- condition: The whole machine is over the forks.
Fig. 41
Transport by fork truck
Lifting cradle
Pre --- condition: No pressure on the sides of the machine cabinet.
Fig. 42
1
12.5
Transport by lifting cradle
Spreader bar
Disposal
Pre --- condition: Machine is de---commissioned.
The sealed refrigerant circuit still contains both refrigerant and oil.
Both must be drained and disposed of by an authorised body.
12 --- 82

When disposing of a machine, drain out all liquids and remove dirty filters.
Parts contaminated with cooling oil must be disposed of in accordance
Completely drain the cooling oil from the machine.
Remove used ail filter and separator cartridge.
Hand the machine over to an authorized disposal expert.
12 --- 83
Annex
13
Annex
13.1
Conformity
Machines with CE mark conform to European directives and may be operated in the EU.
A Declaration of Conformity is provided with the machine.
13.2
Diagrams and Drawings
13.2.1
Pipeline and instrument flow diagram (P&I diagrams)
13 --- 84
Appendix
13.2.2
Pipeline and instrument flow diagram (option C1)
13 --- 90
Appendix
13.2.3
Dimensional drawing
13.2.3.1 Air cooling (option K1)
13 --- 96
Appendix
13.2.4
Electrical diagram
13 --- 99

Manual de Servicio ASD-T

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Manual de Servicio ASD-T

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SERVICE MANUAL

Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

Handling the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16

Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16

Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 33

Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24

Before Initial Start ---up (or Recommissioning) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37

Event Recognition and Fault Rectification . . . . . . . . . . . . . . . . . . . . . . 9 --- 41

Alarms (machine shut ---down, red LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41

11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 74

Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 74

Ordering Maintenance Parts and Operating Materials . . . . . . . . . . . . . . . . . . . .

12 De ---commissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . 12 --- 81

Three---phase star (wye); four wire; earthed neutral . . . . . . . . . . . . . . . . . . . . . . .

Regarding this Document

Regarding this Document

Handling the Document

certificate of acceptance / operating instructions for the pressure vessel

Request the supply of any missing documents from KAESER.

Symbols and Identifications

Here are consequences of ignoring the warning notice.

Consequences of ignoring the warning

Regarding this Document

Miscellaneous notices and symbols

This indicates important information.

167 --- 200

167 --- 200

167 --- 200

Maximum elevation [ft]

Rated pressure [psig]

Blow--- off setting of the safety relief valve [psig]

Free air delivery (FAD)

Motor and Performance

Rated speed [rpm]

Cooling Oil Volumes

Total charge [gal]

Additional volume [gal]

Three ---phase star (wye); four wire; earthed neutral

Three ---phase star (wye); three wire; earthed neutral

Power supply specifications

Rated power supply 460V 10%, 3 --- ph, 60Hz

Internal Heat Recovery (option W2 / W3)

If the heat transfer medium outlet temperature is to be kept constant, the

Maximum working pressure of the heat transfer

Flow rate [gpm]

Flow rate [gpm]

Pressure drop [psig]

(in relation to 100 psig working pressure)

Maximum permitted working pres230

Safety and Responsibility

Safety and Responsibility

Safety and Responsibility

Danger from electric current

Touching electrically energized components can cause serious injury or

no one is working on the machine,

Danger from released spring force

There is considerable danger of injury or death from the release of

Safety and Responsibility

Danger from released compressed air

Injury and/or contamination can result from breathing compressed air.