SERVICE MANUAL USE

Screw Compressor
Model: CSD 75
GL---Nr.: 100265_00060---00 01

L . . . . . . . . . . . . . . . . . . . . . . . . . . Volt L Cabinet heaters

L Wye---Delta Start L 115 V receptacle
L D.O.L. Start L Outdoor modification
L . . . . . . . . . . . . . . . . . . . . . . . . . . psig L Rainhoods
L ............................. L Switchable Modulation
L ............................. L Synthetic lubricant . . . . . . . . . . . . . . . . . . .
L Wiring Diagram: L Food Grade lubricant . . . . . . . . . . . . . . . . .
..............................

Serial No.: ...............................................

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 Table of Contents
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1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.5 Set Point of the Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Greasing the Electrical Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
1.10 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.2 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.3 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.4 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.5 Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.6 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.1 Proper use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.3 Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12
5.2 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12
5.3 Identification of the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.4 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.5 DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 16
5.6 QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 17
5.7 VARIO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 18

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.1 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.2 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20
6.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20

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7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22

7.1 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . 7 --- 22
7.2 Points to be Observed before Starting the Compressor Unit . . . . . . . . . . . . . . . 7 --- 22
7.3 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 24
7.4 Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.5 Motor Overload Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.6 Motor Overload Protection Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
7.7 Setting the Air System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
7.8 Measures to be taken before Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27
7.8.1 Pour a small quantity of oil into the air inlet port . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27
7.8.2 Running the compressor in idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.2 SIGMA controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.3 Emergency Stop Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.3.1 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.3.2 Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.4 Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.5 Acknowledgement of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.6 Acknowledgement of Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 31

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 32
9.1 Observe the following rules during all maintenance and servicing work: . . . . . 9 --- 32
9.2 Location of maintenance doors and cover panels . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 33
9.3 Regular Maintenance (Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 34
9.4 Cleaning the Oil Cooler and Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 35
9.5 Cleaning or Replacing the Filter Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.6 Cleaning or Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.7 Maintaining the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.8 Testing the Safety Relief Valve on the Oil Separator Tank . . . . . . . . . . . . . . . . . . 9 --- 38
9.9 Venting the compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.10 Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.10.1 Removal and replacement of the oil filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.11 Topping off the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 42
9.12 Oil Change (Oil Separator Tank and Oil Cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 44
9.12.1 Oil change using external pressure source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 45
9.12.2 Oil top ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
9.12.3 Draining the oil using own compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.12.4 Procedure for putting back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.13 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.14 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 51

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52

10.1 Service parts and maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.2 Service and Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52

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11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 53
11.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 53
11.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 72
11.3 Trouble shooting: Possible cause---Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 73
11.3.1 Airend temperature is too high (greater than 167•F---200•F) . . . . . . . . . . . . . . . 11 --- 73
11.3.2 Motor overload relay switches the unit off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 73
11.3.3 Compressor is running but produces no pressure . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 74
11.3.4 Oil leaks out of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 75
11.3.5 Full---load/Idle sequence occurs too frequently (short cycles) . . . . . . . . . . . . . . 11 --- 75
11.3.6 Safety relief valve blows off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 75
11.3.7 Oil inside the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 75
11.3.8 Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 76

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 Technical Specification

1 Technical Specification

1.1 Compressor Unit

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CSD 75
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . 125 psig
Minimum gauge working pressure . . . . . . . . . . . . . . . . . . . . . . 80 psig
Free air delivery at max. gauge . . . . . . . . . . . . . . . . . . . . . . . . 361 cfm
working pressure
Operating temperature approx. . . . . . . . . . . . . . . . . . . 167 --- 200 EF
(Varies with ambient temperature and operating conditions)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870 lbs
Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . T 9901.00
P & I flow chart . . . . . . . . . . . . . . . . . . . . . . . FCSDSTL---0001.00
(Pipework and instrument flow chart)
Electrical diagram . . . . . . . . . . . . . . . . . . . . SCSD75.L---U1051.00

1.2 Noise Level

Noise level to CAGI---Pneurop . . . . . . . . . . . . . . . . . . . . . . . . . . 69 dB(A)
at 1 m distance (free sound field measurement)

1.3 Motor
Compressor motor:
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 hp
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm
Specification class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC
Fan motor:
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 hp
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Specification class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC

1.4 Electrical Connection

Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 V 3---phase
Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . 125 A
Recommended power supply cable (Cu multi---stranded )
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/0 AWG
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.

Select multi-- strand copper core wire at 40•C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.
For electrical power supply please refer to chapter 2.3 and 6.3

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 Technical Specification

1.5 Set Point of the Safety Relief Valve

80---125 psig Compressor Unit --- Activating pressure . . . . 155 psig

1.6 Installation Requirements

Max. height above sea level of the place of installation . . 3000 ft.
(for all heights above please contact authorized KAESER distributor)
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 EF
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 EF
Min. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . . 40 EF
Max. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . 115 EF
Air inlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 sq.ft.
Exhaust air for solution A (see chapter 6.1):
Forced ventilation with exhaust ventilator . . . . . . . . . . . . . 11770 cfm at static pressure of
0.4 inches water column
Exhaust air for solution B (see chapter 6.1):
Exhaust air used for space heating:
Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . 27 1/2 x 27 1/2

1.7 Oil Capacities

Total oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3/8 gal
After oil change or after long period of storage
Quantity required for prelubrication of the airend . . . . . . . . . . . 1 quart
(Refer to chapter 7.8.1)
Difference in oil volume between minimum and maximum levels
Top off volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 quart

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 Technical Specification

1.8 Oil recommendations

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 oil can allow the formation of acids,
causing extensive internal corrosion. Water may be condensed decreasing the oil’s lubric-
ity.
Oil in rotary compressors does much more than lubricate. During the compression pro-
cess, it acts as a sealant in the airend which is important for maximum efficiency. The lubri-
cant also absorbs much of the heat of compression to cool the airend and reduce the tem-
perature of the compressed air. It’s not enough that a compressor fluid lubricates well, it
must stand up to the heat, pressure and contaminants that are present in every air com-
pressor.
KAESER COMPRESSORS 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.

RECOMMENDED KAESER LUBRICANTS

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*

First Oil Change Subsequent Oil

Change

M---460 ISO 46 Semi---Synthetic Lubricant 2,000 Hours 4,000 Hours

S---460 ISO 46 Synthetic Lubricant 6,000 Hours 8,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
M -- SERIES SEMI -- SYNTHETIC LUBRICANTS
- M---Series SIGMA compressor fluids are the highest quality petroleum lubricants.
M---460 is specially blended to provide reliable performance in KAESER screw com-
pressors.
S-- SERIES SYNTHETIC LUBRICANTS
- S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. These ”synthetic” lubricants begin as high quality petroleum feed stock.
They are then refined, processed and purified into fluids with very consistent molecular
structure. These oils are carefully blended to produce extremely consistant lubricants
with superior properties. SIGMA synthetic lubricants feature all the advantages of both
PAO and diester fluids.
- S---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

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 Technical Specification

21 CFR §178.3570 and is USDA H---1 approved. FG---460 is approved for canning,
food packing, meat and poultry processing and other applications where incidental
food contact may occur.

SPECIALTY KAESER LUBRICANTS

(Refer to product information to determine suitability.)

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*

First Oil Change Subsequent Oil

Change

S---680 ISO 68 Synthetic Lubricant 6,000 Hours 8,000 Hours

FG---460 ISO 46 Food Grade Synthetic
Lubricant 3,000 Hours 4,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
General Information
KAESER synthetic lubricants should be stored in a protected location to prevent contami-
nation. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER syn-
thetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classi-
fied as a fire---resistant fluid. It has a flash point above 460•F. Since the user has total con-
trol over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
Regardless of the lubricant selected, the KAESER Sigma lubricants will separate readily
from water. If condensate occurs it can easily be removed. Let the compressor sit so that
any water can drain back to the separator tank and separate to the bottom. See chap-
ter 9.12 proper draining procedure.

Compatibility of KAESER Sigma Lubricants

All the above listed KAESER Sigma lubricants are similar to mineral oil in their compatibility
with paints, seals, gaskets and hoses. The typical precautions are required when changing
over from mineral oil to KAESER synthetic hydrocarbon based lubricant.
Never mix lubricants of different types or brands.
When switching from mineral oil to a synthetic oil, the plant’s system materials must be
re---evaluated. Certain plastics are not compatible with synthetic oils. The following is a par-
tial list of acceptable and not recommended materials:

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 Technical Specification

ACCEPTABLE NOT RECOMMENDED

Viton Celcon PVC

High Nitrile Buna N Neoprene ABS
Teflon SBR Rubber
Epoxy Paint Low Nitrile Buna N
Oil Resistant Alkyd Acrylic Paint
Nylon Lacquer
Delrin Polystyrene

Attention! Polycarbonate bowls can be etched by any synthetic lubricant.

We recommend replacement with metal bowls, or the addition of metal
guards.

1.9 Greasing the Electrical Motor

Relubricate the compressor motor bearings:
Relubricate interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 h*
Grease volume per bearing for regreasing . . . . . . . . . . . . . 1.25 oz
Recommended lithium base saponified bearing grease:
- Exxon Unirex N 3
Replace the compressor motor bearings:
Under normal operating conditions, after . . . . . . . . . . . . . 35000 h*
(ambient temperature up to 77EF)
Under unsuitable operating conditions, after . . . . . . . . . . 20000 h*
(ambient temperature 78EF or more)
at the latest after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 years
* operating hours
Replace the fan motor bearings:
Under normal operating conditions, after . . . . . . . . . . . . . 12000 h*
(ambient temperature up to 77EF)
Under unsuitable conditions, after . . . . . . . . . . . . . . . . . . . . 6000 h*
(ambient temperature 78EF or more)
but no later than . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 years
* operating hours

1.10 Dimensional Drawing

(see following page)

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 Technical Specification

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 Safety

2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting this
compressor package into operation and before carrying out any maintenance.

2.1 Explanation of Symbols and References

This symbol is placed before all references to safety where danger to
life and limb can occur during work. It is especially important that
these rules are observed and that extreme care is taken in these
cases. For their own protection, all other users must be informed of
these safety rules. Observe general safety and accident prevention
regulations as well as the safety rules laid down in this service man-
ual.

Attention! This symbol is placed by text where considerable attention must be

paid so that recommendations, regulations, references and correct se-
quence of work are adhered to and that damage and/or destruction of
the compressor unit and/or other equipment is prevented.

This symbol identifies environmental protection measures.

 This symbol indicates operations to be carried out by the operator or

service technician.

- This bullet identifies listings.

Explanation of warning labels

Beware of hot surface. Do not touch surface; danger of burning.

Beware of life -- threatening electricity. Do not touch electrical compo-

nents; danger of electric shock.

Beware of rotating parts. Do not touch rotating parts as this can cause
pinching/injury.

2.2 General Safety Precautions

Work on power driven systems may only be carried out by trained or
specialized personnel.

Prior to working on electrical systems of the compressor always per-

form the following steps in the sequence shown.

1. Lock the main disconnect in the ”off” position in accordance with

applicable lock out/ tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

2. Ensure the package cannot be switched on again

3. Check that no voltage is present

4. Lock the isolation shut-- off valve in the ”closed” position and vent
all compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out pro-
cedures (example: OSHA CFR 29 § 1910.147).

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 Safety

Attention! Any alterations or reconstruction carried out without the prior written
authorization of KAESER COMPRESSORS Inc. will invalidate the war-
ranty.

Do not weld on or near any pressurized components (e.g., pipes,

tanks, fittings) or make any modifications that require heat treatment.

- Do not allow open flame and flying sparks at the installation site.
- Take necessary precaution when welding on or near the compressor package to en-
sure that sparks or high temperatures cannot cause fire or explosion.
- Ensure that the compressor package is supplied only with clean uncontaminated air.
- Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
unless special measures have been agreed upon between the manufacturer and the
customer.
- Perform oil changes according to the service manual or at least once annually (see
chapter 9.11).
- Do not mix cooling oils of different types.
- Maintain and monitor the operating temperature according to the manufacturer’s
specifications to avoid build ---up of condensate or varnish in the oil circuit (see
chapter 1.1).
- Use only cooling oils recommended by the manufacturer (see chapter 1.8).
- If maintenance work is carried out on any part of the oil circulation system, top off the
oil in the oil separator tank to the maximum level, run the compressor and keep it
under constant observation for a short period. Check the oil level again and top off
with oil to replace the oil taken up by the piping and the cooling system.
- Operation of compressor package is not recommended if the differential pressure
across the separator cartridge is greater than 14.5 psi. Check periodically.

2.3 Electrical Power Supply

Attention! The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.

Compressor packages must be installed with a lockable main discon-

nect and fuses or other short-- circuit and ground fault protection de-
vice.

For fuse and wire recommendations, see chapter 1.4

Please note that the conductors, fuses and procedure are KAESER’s
recommendations. These recommendations do not supersede other
applicable codes.

2.4 Spare Parts

Safe and reliable operation of the compressor package is guaranteed only with KAESER
original spare parts and KAESER SIGMA cooling oil.

2.5 Compressed Air System

If a compressed air system is extended or changed, verify that the blowoff pressure and
capacities of the safety relief valves on the air receiver tanks and in the system match the
rating of all the compressor packages installed.

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 Safety

2.6 Environmental Protection

Condensate drainage

The condensate accumulating during compression must be fed via a

suitable drainage system, collected in special canisters and disposed
of according to environmental regulations.

Maintenance materials/wear items/replacement parts

Ensure that all wear items, maintenance and replacement parts accu-
mulating during operation of the compressor package are disposed of
according to environmental regulations.

The following points must be observed:

Avoid contact with skin and eyes.

Do not inhale vapors and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.

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 General

3 General

The service manual must always be available for use at the location of
the compressor package.

3.1 Proper use of the Compressor

The compressor package is intended solely for the purpose of generating compressed air.
Any further use outside of this purpose is considered improper. The manufacturer cannot
accept liability for any damage caused by such improper use; the user alone is liable for
any risks incurred.
Proper use of the compressor also includes adherence to the installation, removal, applica-
tion, operational and maintenance instructions laid down by the manufacturer.

If the compressor package is operated in an air distribution network, the maximum network
pressure may not exceed 232 psig.

3.2 Improper use

Never direct compressed air toward persons. Compressed air is a con-
centrated form of energy and as such is dangerous to life.

3.3 Compressed Air Treatment

Never use compressed air from oil injected compressor packages for
breathing purposes and production methods where the air has direct
contact with food, without subjecting the compressed air to additional
treatment.

3.4 Copyright
KAESER COMPRESSORS, INC.
All rights reserved. No part of this manual may be reproduced in any form without per-
mission of KAESER COMPRESSORS, INC.

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 Transport

4 Transport

4.1 Transport Instructions

We recommend a fork lift truck or lifting equipment for transporting the compressor pack-
age to avoid damage to the cabinet and framework.

min. 35” min. 63”

Measurements in inches

Spreader bar

Attention! Do not exert any side forces on the compressor package when trans-
porting with lifting equipment!

4.2 Packaging
The packaging provided with this compressor as delivered is intended to safeguard the
package against normal road transport damage. Please dispose of in an environmentally
friendly way and arrange for it to be recycled if possible.

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 Construction and Operation

5 Construction and Operation

5.1 Principle of Compression

The stationary compressor package is fitted with a single stage, oil---injected airend. The
two rotors, the driven male rotor and the female rotor, both mounted in antifriction bear-
ings, are fitted into the airend. As the rotors rotate, air is drawn into the upper side through
the inlet port and is compressed on the lower side. The oil that is injected into the lower
side absorbs heat generated by compression, prevents metal to metal contact between
the rotors, seals the rotors and the housing from each other and also lubricates the antifric-
tion bearings. The compressed air and oil mixture leaves the airend via the discharge port.

4 5 1 2 3
1 Drive shaft 4 Male rotor
2 Oil injection 5 Female rotor
3 Discharge port 6 Air inlet port

5.2 Brief Description

The compressor block is driven by an electric motor via a coupling.
An oil separator cartridge is fitted into the oil separator tank allowing practically oil free
compressed air supply.
The control system of the compressor unit ensures that compressed air is generated within
the set pressure limits.
Safety devices protect the compressor unit against failure of important systems through
automatic shut ---down.
The fan ensures sufficient cooling air flow to the air---cooled oil cooler and air aftercooler.

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 Construction and Operation

5.3 Identification of the Components

Position details in ( ) correspond with the Pipe and Instrument Flow Diagram
(P & I Diagram)

8 4

5 2 6 3
1 Inlet valve (2) 6 Control cabinet
2 Coupling (53) 7 Oil separator tank
3 Drive motor (3) 8 Air filter (1)
4 Oil filter (10) 9 Oil/air aftercooler (11/13)
5 Airend (4)

5.4 Pipe and Instrument Flow Diagram (P & I Diagram)

(see following pages)

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 Construction and Operation

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 Construction and Operation

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 Construction and Operation

5.5 DUAL Control

p
max
Pressure

p
min

1 2 3 4 5
Full load t1 t2
Motor power

Idle
Standstill
Time
In DUAL Control (combined idle and start ---stop) the compressor normally runs at full --
load, idle or standstill.
The controller regulates the compressor package between full -- load and idle.
If the compressor package runs in idle for longer than the preset period (1) to (2), for
example t1 = 6 min, the drive motor is stopped completely (2). When the lower switching
point p min (3) is reached the compressor package is automatically started again. Pressure
rises to the upper switching point p max (4), and the compressor package switches to idle. If
the pressure falls again to, for example, p min (5) within a shorter period (4) to (5), then the
compressor is automatically switched from idle to full---load.

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 Construction and Operation

5.6 QUADRO Control

p
max
Pressure
pmin

Full load
Motor power

Idle
Standstill
1 2 1 3 1 4 1 2 1 4 5 1
Time
tp rise
tp decay

Running period
Idle/
standstill period
Run ---on period

Stop point for the running period or idle / standstill period

pmax upper switching point

pmin lower switching point

tp rise pressure rise time (the time during which the air system pressure rises
from the lower to the upper switching point)
tp decay pressure decay time (the time during which the air system pressure decays
from the upper to the lower switching point)

Functional description
Two fixed periods --- the running period and idle/standstill period --- are taken as the crit-
erium for selection of the operating mode of the compressor package when the air mains
pressure reaches the upper switching point. These two periods are set according to the
maximum permissible cut ---in frequency of the compressor motor.
The running period starts every time the compressor package is switched on. It lasts as
long as the compressor motor runs and stops when the compressor package switches to
full stop.
The idle/standstill period starts every time the operating mode changes from full load to off
load running. It runs during idle and also when the compressor package is switched to
standstill after the idle period. It stops when the compressor package switches to full load.
Every switching off point is delayed by the run ---on period, during which time the com-
pressor package vents.
The following switching cycles are possible:
- If the air systems pressure decays to the lower switching point, the compressor pack-
age switches to full load (1) irrespective of its previous operating mode. If the com-
pressor motor was at a standstill the opening of the inlet valve is delayed to allow an
unloaded compressor package start.

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 Construction and Operation

- If the air systems pressure rises to the upper switching point and the running period
has already expired, the compressor package is switched off after the run ---on period
has expired (2).
- If the air systems pressure rises to the upper switching point before the running period
has expired then the pressure decay time of the previous switching cycle is taken as
the criterium for the selection of the operating mode:
-- If the pressure decay time tp decay was longer than the period set for the idle/standstill
period, the compressor is switched to standstill after the run ---on period has ex-
pired (3).
-- If the pressure decay time tp decay was shorter than the period set for the idle / stand-
still period, the idle mode is selected (4), that is, the inlet valve closes and the com-
pressor is vented with running motor. When the running period expires the com-
pressor package switches to standstill only after the run ---on period has also
expired (5).

5.7 VARIO Control

Functional description:
The idle period is automatically lengthened or shortened by the variable idle control in rela-
tion to the number of motor starts. The number of motor starts during the preceding hour
are measured.
A high switching frequency leads to longer idle periods.
A low switching frequency leads to shorter idle periods.

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 Installation

6 Installation

6.1 Installation Requirements

Attention! The compressor should be mounted on level surface.
For any special application please consult with the manufacturer.
Safe operation of the compressor package is only ensured if the ambient temperature re-
mains within the limits stated in chapter 1.6).
If the compressor is used in the open, take care that it is protected against the direct rays
of the sun and against the ingress of dust and rain.
Install the compressor according to the following diagram. Adhere to the minimum dis-
tances shown to allow free access to the compressor package.
Adequate ventilation of the compressor space is ensured only if the minimum values (see
chapter 1.6) are adhered to.

A
40

B
b

min. 160
80
min. 200

Exhaust
channel
B
Exhaust
channel
B
h A
Exhaust ventilator
min. 140

Air inlet
opening

Measurements in inches

Solution A: Forced Ventilation

The ventilator intended for the compressor room must provide adequate ventilation in rela-
tion to the size of the compressor package (see chapter 1.6).

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 Installation

Solution B: Exhaust Air used for Space Heating

The hot air is forced through a conduit (see chapter 1.6) into the room to be heated.
Attention! Consult the manufacturer with regard to length of conduit and for
maximum allowable pressure drop for this compressor package.
Safe operation of the compressor package is guaranteed only if the temperature limits (see
chapter 1.6) of the cooling air are adhered to.
Attention! In confined places, the minimum distance between one side of the
compressor package and any wall can be reduced.
It is imperative that the minimum distance shown in the drawing is kept
to, to allow servicing work to be carried out without hindrance.
16

Measurements in inches

6.2 Connection of the Compressed Air Supply

Attention! The package is set up ready to operate. Connect the discharge outlet
of the compressor to the system pipework using a flexible hose line
(or axial compensator) and isolation shut-- off valve with drain.
Use the NPT adapter if necessary.

6.3 Electrical Connection

The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.

For fuse and wire recommendations, see chapter 1.4

The compressor is wired ready for connection to the main supplies. Feed the supply cable
with cores marked L1, L2, L3 and PE through the cable inlet in the base frame into the con-
trol box and connect to the terminals marked L1, L2, L3 and PE in this box.
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.

Select multi-- strand copper core wire at 40•C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.

Wire temperature rating:

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 Installation

1.25 x FLA wire correction factor

(see chapter 1.4) temperature rating for 40•C
ˆ 100A 60•C 0.82
> 100A 75•C 0.88

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 Initial Start

7 Putting into Operation

7.1 Points to be Observed before Putting into Operation

Every compressor package is given a test run at the factory and carefully inspected before
shipment. The test run confirms that the package conforms to the specification data and
runs perfectly. However, the compressor package could be damaged during transport. For
this reason, we recommend that the package be examined for possible shipping damage.
It is recommended that an operator observe the compressor package carefully during the
first hours of operation for any possible malfunction.

Attention! Important functional components in the compressor package (such as

minimum pressure check valve, safety relief valve, inlet valve and com-
bination valve) are adjusted and fitted to factory standards and specifi-
cations. Alterations to these components are not allowed without prior
written authorization with the manufacturer.

Do not disassemble the minimum pressure check valve, safety relief

valve and inlet valve. They are heavily spring loaded.

Disassembly by unqualifed personnel may result in personal injury or

equipment damage.

7.2 Points to be Observed before Starting the Compressor Unit

ANY NON -- OBSERVANCE OF THIS OR OTHER REFERENCES (WARN-
ING; ATTENTION; DANGER ) CAN LEAD TO ACCIDENTS CAUSING IN-
JURY TO PERSONS OR DAMAGE TO EQUIPMENT.

If a power failure occurs, the compressor package starts again auto-

matically (normal setting) provided the line pressure is lower than the
pressure threshold parameter entered in SIGMA CONTROL.

Do not operate the compressor with open maintenance doors or with

cover panels removed as personnel could be injured by rotating parts
and electrical equipment.

 Remove all packaging materials, tools and transport securing devices on and in the
compressor package.
- The operator is expected to practice safe working techniques and to follow all recom-
mended operating and safety regulations when operating this compressor package.
- The operator of this compressor unit is responsible for its safe operating condition.
- Do not operate this compressor unit in locations where high dust conditions, poison-
ous, or inflammable gases could exist.
- Do not connect the compressor package to a supply voltage other than that stated on
the nameplate.
- Do not install the compressor package in a location subject to freezing temperatures.
The air temperature requirements at the air intake must be complied with (see
chapter 1.6).
- If exhaust air ducts are to be installed the duct cross section must be equal or larger
than the cooling air outlet of the compressor package and may not exceed the per-
mitted pressure loss prescribed by the compressor manufacturer.

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 Initial Start

- During installation of the compressor unit, ensure that a distance of at least 40 ” is

kept between the air intake of the unit and any wall.
 Check the oil level in the oil separator tank (see chapter 9.11).
- Check that the airend rotates in the correct direction (see chapter 7.4).
 The ball valve (6.6 and 11.6, see chapter 5.4) must be closed.
 The ball valve (20, see chapter 5.4) in the vent line must be open.

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Check all screws on the electrical connections for tightness and

tighten if necessary (carry out this check again after 50 hours of oper-
ation).

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 Initial Start

7.3 Checklist
 Is the floor at the place of installation solid and level?
 yes  no
 Is the space large enough for the compressor package or its components?
 yes  no
 Are inlet and exhaust air apertures available in sufficient size and number?
 yes  no
 Are all components of the compressor package easily accessible?
 yes  no
 Is the power supply cable of sufficient cross---section?
(have electrical connection carried out by qualified electrician or company familiar with
local conditions)
 yes  no
 Is a shut off valve fitted by the user?
 yes  no
 Is a flexible connecting hose or axial compensator fitted between the compressor
package and the compressed air system?
 yes  no
 Have all screws, bolts and electrical connections been checked for tightness?
 yes  no
 Has the oil level in the oil separator been checked?
 yes  no
 Is a main disconnect switch fitted (suited to the motor starting characteristics)?
 yes  no
 Has the setting of the drive motor overload current trip been checked?
 yes  no
 Have you ensured that there are no other air components located in the exhaust air flow
of the compressor package?
 yes  no
 Have service personnel been instructed on safety regulations?
 yes  no

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 Initial Start

7.4 Direction of Rotation Check

Attention! The compressor is wired for connection to a clockwise phase se-

quence power supply.

A check of the direction of rotation can be made by testing the phase sequence.
Arrows showing the direction of rotation are located on the motor and on the airend hous-
ing.
 On your initial start, ”bump” the unit and verify the direction of rotation.
If the direction of rotation is incorrect, change over the supply conductors L1 and L2.

Attention! If the airend rotates in the wrong direction, the compressor is auto-
matically shut down by the safety air pressure switch (4.2, see
chapter 5.4).

7.5 Motor Overload Relay Adjustment

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart. See
chapter 2.3 for the main disconnect switch.

The relay is set to the standard adjustment at the factory.

Compressor motor: Wye -- delta start

In the Wye---delta configuration the phase current is fed through the motor overload relay.
This phase current is 0.58 times the nominal motor current.
For the nominal motor current see motor nameplate.

Adjustment:
To prevent the overload relay from tripping (because of voltage fluctuations, temperature
influences or component tolerances), the value can be set up to 15% higher than the
calculated phase current.

1 Motor overload adjustment

2 Reset button

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 Initial Start

7.6 Motor Overload Protection Switch Adjustment

Before any adjustments are carried out to the compressor package,
lock the main disconnect in the ”off” position in accordance with appli-
cable lock out/tag out procedures (example: OSHA CFR 29 § 1910.147)
to ensure the compressor does not restart.
See chapter 2.3 for the main disconnect switch.

The standard setting is made at the factory.

Fan Motor: direct on-- line start
In direct on ---line start the starting current is fed via the motor overload protection switch.
For the nominal motor current see motor nameplate.
Adjustment:
This can be set to a maximum of 10% higher than the rated motor current to prevent trig-
gering of the motor overload protection switch under conditions of voltage fluctuation.

1 2 3
1 Fan motor overload protection relay
2 Fan motor overload adjustment
3 Reset button

7.7 Setting the Air System Pressure

The air system pressure is preset at the factory. It can be changed in SIGMA CONTROL to
match customer’s operational requirements if the password is known. For further details,
consult the SIGMA CONTROL service manual.

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 Initial Start

7.8 Measures to be taken before Initial Start

Follow the procedure detailed bellow before initial start, after an oil change or if the com-
pressor has not been operated for a period of three months or longer before starting the
compressor:

7.8.1 Pour a small quantity of oil into the air inlet port
Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Do not add oil unless the compressor package is completely vented.

See chapter 9.9 to vent the compressor.

 To pour in the oil, unscrew the filler plug (1) on the inlet valve (2) and then pour the
prescribed quantity of oil (see chapter 1.7) into the airend.
 Manually rotate the airend in a counter clockwise direction using the coupling.
 Screw the filler plug (1) back in.
Attention! This oil must be of the same type as the oil used to operate the com-
pressor (see label near the oil filler plug on the oil separator tank).

If no additional oil is available, remove required amount of oil from the

oil separator tank. See chapter 9.12 for this procedure.

If the compressor unit was at standstill for more than 12 months, addi-
tional precautionary steps have to be taken before putting the unit
back into operation. In this case consult the manufacturer.
 Open the isolation shut ---off valve between the compressor and the compressed air
system.
1

1 Filler plug
2 Inlet valve

7.8.2 Running the compressor in idle

At initial start run the compressor package in idle for 20 seconds by pressing the load/idle
key (5, see chapter 8.3.1).
This measure ensures that the compressor package has sufficient time to flood the oil cir-
culation.
If a power failure occurs, the compressor package will start again
automatically (normal setting) when the power is restored provided the
system pressure is lower than the cut-- in pressure entered in the
SIGMA CONTROL.

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 Operation

8 Operation

8.1 Control Panel

1 SIGMA CONTROL
2 EMERGENCY STOP pushbutton

8.2 SIGMA controller

The SIGMA controller (1) is fitted in the control cabinet in the compressor package and
serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor pack-
age is determined by the settings programmed into the controller.
Further details on individual function keys, LEDs and plain text display relating to possible
alarms and service messages, display of events, etc. are given in the service manual sup-
plied for the SIGMA CONTROL controller.

8.3 Emergency Stop Pushbutton

The Emergency Stop pushbutton shuts down the compressor package immediately.
If the Emergency Stop pushbutton is pressed because of an existing hazard, then this
must be eliminated before the compressor package is reset. To accomplish this the follow-
ing procedure must be carried out:
 Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows.
 Acknowledge the alarm message on the controller by pressing the acknowledge
(reset) key. (function keys see chapter 8.3.1.)

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 Operation

8.3.1 Function keys

7
11 8
10 9
6
1

5 2

4 3
1 ON key (“I”) 6 Menu scroll --- DOWN key
2 OFF key (“0”) 7 Menu scroll --- UP key
3 Timer ON/OFF key 8 Escape key
4 Remote ON key 9 Return key
5 Load/idle key 10 Info --- event key
11 Acknowledge (reset) key

8.3.2 Light emitting diodes and plain text display

13
14 12
15

16 19

17
18

20 21
12 Four ---line display 17 Load LED
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning --- maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 Timer ON LED

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 Operation

8.4 Starting and Stopping the Compressor Unit

Attention! Do not start and stop the compressor package with the main discon-
nect switch. The compressor must always be switched ON and OFF
with keys (1) and (2).

To turn the compressor ON (local):

 Switch on the main disconnect switch.
The controller carries out a self---test. The self---test sequence is visible in the display (12).
Afterwards, the green LED (16) illuminates permanently.
 Press the ON key (1)--- LED (19) illuminates.
The compressor status is indicated by LEDs (17) and (18):

Attention! If LED (19) is illuminated and both LEDs (17) and (18) are extinguished
the compressor package is at standstill but on duty.

The compressor package can start at any moment.

To turn the compressor OFF (local):

 Press the OFF key (2) --- LED (19) extinguishes.
 Lock the main disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the compressor
does not restart.
See chapter 2.3 for the main disconnect switch.

8.5 Acknowledgement of Alarms

If an alarm occurs the compressor package is shut down immediately and the red
LED (13) on SIGMA CONTROL flashes.
The bottom line in the display (12) shows the actual fault causing the alarm.
A list of alarms that may occur during operation is included in the SIGMA CONTROL
service manual.
 Remove the fault.
 Acknowledge alarm with the reset key (11) --- LED (13) extinguishes.
The compressor package is now ready to start again.

Attention! If the compressor was shut down with the EMERGENCY STOP push-
button, then reset by rotating the latched pushbutton in the direction of
the arrow before acknowledging the alarm.

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 Operation

8.6 Acknowledgement of Service Messages

When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes.

Attention! Before any maintenance is due an initial warning is displayed to allow

coordination of service and maintenance personnel and provision of
necessary servicing materials. (lubricants, spare parts, etc.).

Maintenance due is shown in the display (12).

A list of service messages that may occur during operation is included in the SIGMA
CONTROL service manual.
 Carry out the maintenance work.
 Acknowledge service message with the reset key (11) --- LED (15) extinguishes.

Attention! When the respective maintenance has been carried out, the remaining
interval period (programmed interval until the next maintenance is due)
must be reset.

Detailed information on resetting service counters is to be found in the service manual for
SIGMA CONTROL.

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 Maintenance

9 Maintenance

9.1 Observe the following rules during all maintenance and servicing work:
Work on power driven equipment may only be carried out by trained or
specialized personnel. Follow all applicable OSHA and local safety
regulations.

If a power failure occurs, the compressor package starts again auto-

matically (normal setting) provided the line pressure is lower than the
pressure threshold parameter entered in SIGMA CONTROL.

Lock the main disconnect switch in the ”off” position in accordance

with applicable lock out/tag out procedures to ensure the compressor
does not restart (see chapter 2.3 for main disconnect switch).

Ensure that no maintenance personnel is working on the compressor

unit, that all panels are latched back on again and all maintenance
doors are closed before restarting the compressor unit.

To start the compressor unit see chapter 8.4).

The following points must be observed when handling lubricating and

cooling materials:

Avoid contact with skin and eyes.

Do not inhale vapors and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.

Ensure that all lubricants, consumable materials and replacement

parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental regulations.

Attention! The maintenance hose required to vent the oil separating tank (for
maintenance work such as oil top off, oil change and filter change) is
located under the oil separator tank on the bottom panel.

Attention! If the compressor package is installed directly in front of a wall then

the accessibility of components may be limited.
If necessary, remove further panels.

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 Maintenance

9.2 Location of maintenance doors and cover panels

1 --- Control cabinet door

2 --- 5 Cover panels
2
1
3

5
4

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 Maintenance

9.3 Regular Maintenance (Compressor)

Interval Work to be done See chapter

50 h after initial start Check all electrical connections for tightness

and toghten if necessary

Weekly Check the oil level 9.11

Check the filter mats for contamination 9.5

Indication by Clean or change the air filter* 9.6

SIGMA CONTROL
Change the oil filter* * 9.10

Change the oil separator cartridge* 9.13

1000 h Check the oil cooler and air aftercooler for con- 9.4
tamination

Clean or replace the filter mats* 9.5

2000 h or at least an- Grease the drive motor bearings* 9.7

nually

2000 h Change the oil filter* * 9.10

Proper interval varies. Change the oil* 9.12

See chapter 1.8

6000/12000 h or after Change the fan motor bearings* 9.7

3 years at the latest

Annually Check all electrical connections for tightness

and tighten if necessary

Have the safety relief valve checked by 9.8

authorized KAESER distributor

Every two years Change the air filter* 9.6

20000/35000 h or after Remove motor bearing covers and/or end 9.7

8 years at the latest shields, remove old grease from bearing cavity
and regrease bearings.*

* The maintenance period can vary depending on the cycle rate and environmental
conditions.
* * Not to exceed 2000 service hours.
We urgently recommend that a record is kept of the maintenance work done (see chap-
ter 9.14).

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 Maintenance

9.4 Cleaning the Oil Cooler and Aftercooler

The oil and air aftercooler must be checked for clogging regularly. Heavy contamination
could lead to excessive high temperatures in the oil circulation system.
See regular maintenance schedule for cooler Maintenance interval (chapter 9.3).
 Switch off the compressor package (see chapter 8.4).

Lock the main disconnect switch in the ”off” position in accordance

with applicable lockout/tagout procedures to ensure the compressor
does not restart.

 If the cooler is only lightly contaminated, brush off and vacuum dirt.

Attention! Do not use any sharp cleaning instrument that may damage the cooler.

Attention! If the coolers are badly contaminated have them cleaned by authorized
KAESER distributor.

5
1 Air cooler
2 Oil cooler
3 Oil filter
4 Shut ---off valve
5 Hose coupling for oil cooler

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 Maintenance

9.5 Cleaning or Replacing the Filter Mat

Clean the filter mat every week depending on the dust content of the intake air and replace
if necessary as detailed in the maintenance schedule (see chapter 9.3).
 Switch off the compressor package (see chapter 8.4).

Lock the main disconnect switch in the ”off” position in accordance

with applicable lockout/tagout procedures to ensure the compressor
does not restart.

2
1 Filter mat, control cabinet fan
2 Plastic covering

Cleaning:
Rinse the mat in warm water ( approximately 105•F), if necessary, use a mild detergent
soap to rinse out oily dust. The mat can also be tapped, vacuum cleaned or blown out with
compressed air (not in excess of 30 psig).

Attention! If the mat is heavily soiled or has been cleaned often (maximum five
times), replace it.

9.6 Cleaning or Replacing the Air Filter

Clean the air filter when the corresponding indicator on the SIGMA CONTROL illuminates
(see chapter 8.1). Change the air filter cartridge no later than two years.
 Stop the compressor unit (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures to ensure the compressor does
not restart.

3
4
1

1 Remove fastening clips to open the filter housing

2 Air filter
3 Dust collector
4 Air filter cartridge

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 Maintenance

 Remove cover panel (3, siee chapter 9.2).

To open the air filter housing:
 Open the snap fasteners (1) on the dust collector (3) and remove the dust collector (3)
with the insert.
 Take the insert out of the dust collector (3).
 Pull out the air filter cartridge (4) by turning slightly.
 Clean the air filter housing, dust collector, insert and sealing surfaces.
Cleaning the air filter cartridge (4) by tapping:
 Tap the air filter cartridge several times on the front with the ball of the hand.

Attention! Do not use excessive force otherwise the air filter cartridge may be
damaged.

 Clean all sealing surfaces.

Cleaning the air filter cartridge with compressed air:

 Use dry, compressed air blowing at a pressure of not more than 30 psig at a slant
from the inside to the outside of the air filter cartridge surfaces.

Attention! Do not clean the air filter cartridge with fluids. If the air filter cartridge
is heavily contaminated or was already cleaned several times (max.
five times), replace.

Compressed air shall not be used for cleaning purposes except where
reduced to less than 30 psig and then only with effective chip guarding
and personal protective equipment. (OSHA CFR 29 § 1910.242)

To close the air filter housing:

 Insert the air filter cartridge (4).

Attention! Note the insertion mark on the dust cap.

 Guide the insert into the dust collector (3).

 Put back the dust collector (3) and close the snap fasteners (1).
 Close all maintenance doors and reattach all cover panels.

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 Maintenance

9.7 Maintaining the Electric Motor

Compressor motor:
The bearings are greased via fittings on the tops of the bearing end shields.
Initial greasing of the bearings is carried out by the manufacturer.
See chapter 1.9 for greasing periods, quantity and approved greases.
 Remove cover panels (2 and 3, see chapter 9.2).
 Clean the fittings before greasing to avoid dirt being carried in with the grease.
 Grease the bearings on both ends of the shaft with the motor running.
 Close all maintenance doors and reattach all cover panels.

Attention! The motor has no outlet bores for the grease. Therefore, care must be
given to ensure that the bearings are not over greased. Please refer to
section 1.8 for proper grease quantities. Also, bearing cavity must be
cleaned and regreased every 20,000 hours to 35,000 hours, depending
on environmental conditions.

The bearing covers and/or the end shields must be removed and the
old grease disposed of according to environmental regulations.

Fan motor:
The electrical motor bearings are permanently greased.

Attention! Have the motor bearings replaced by an authorized KAESER distribu-

tor in accordance with the maintenance schedule (see chapter 1.9).

9.8 Testing the Safety Relief Valve on the Oil Separator Tank
To test the set point of the safety relief valve, the compressor must be run so that its dis-
charge pressure exceeds the maximum pressure set on the SIGMA CONTROL.
See chapter 1.5 for the safety relief valve activating pressure.

Attention! Have the safety relief valve tested by an authorized KAESER distribu-
tor in accordance with the maintenance schedule (see chapter 9.3).

For more details see SIGMA CONTROL manual.

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 Maintenance

9.9 Venting the compressor unit

 Switch off the compressor unit (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures to ensure the compressor does
not restart.

Lock the isolation shut-- off valve in the ”closed” position and vent all
compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out pro-
cedures.

The oil circulation system of the compressor package vents automatically.

Venting the oil separator tank:

10
A
1
B

2
8
3

5
7
4
6

9 a

c b
low

high

11
12

1 Ball valve 4 Filler plug 8 Maintenance hose (6 ---8)

A shut (oil top --- off) 9 Oil level indicator
B open 5 Oil separator tank 10 Hose coupling
2 Pressure gauge 6 Nozzle 11 Ball valve (oil drain)
3 Hose coupling 7 Ball valve 12 Hose coupling

 Remove cover panel (3, siee chapter 9.2).

 The pressure gauge (2) on the oil separator tank must indicate zero psig.

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 Maintenance

Oil mist can escape when the oil separator tank is vented.

When inserting the maintenance hose into the compressor’s hose

couplings, always have the ball valve closed and the hose end se-
cured before slowly opening the ball valve. Beware of air/oil mist that
could blow out of the hose. Unrestricted air/oil flow through the hose
end will result in a whipping action which could cause severe injury or
death.

 Insert the maintenance hose (6) --- ball valve closed --- in the hose coupling (3) on the
oil separator tank (5).
 Slowly open the ball valve (7). The residual pressure in the oil separator tank escapes.
 Remove the maintenance hose (8) from the hose coupling (3) on the oil separator
tank.
Venting the air cooler:

After a compressor package is vented, there is still line pressure up to

the minimum pressure/check valve. For this reason, the compressor
package must be shutoff from the air main (downstream shutoff valve).
If no shutoff valve is installed, the complete air distribution network
must be vented.

 With the ball valve (7) closed, insert the male coupling of a maintenance hose in the
connecting point of the minimum pressure/check valve, then slowly open the ball
valve to vent the air cooler.
 Disconnect the maintenance hose from the hose from the minimum pressure/check
valve.

Close all maintenance doors and panels correctly before starting the
compressor package.

9.10 Oil Filter Change

Hot oil; beware of scalding.

Changing the oil filter element is recommended after the interval quoted in the regular
maintenance table (see chapter 9.3) or when the corresponding service message is dis-
played on SIGMA CONTROL (see chapter 8.1). The element must be changed after every
oil change.

9.10.1 Removal and replacement of the oil filter cartridge

 Stop the compressor package under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.

 Venting the compressor package (see chapter 9.9).

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 Maintenance

 Remove cover panel (2, siee chapter 9.2).

1 Oil filter cartridge

2 Turn in this direction to unscrew the cartridge

 Twist the used or contaminated oil filter cartridge counter clockwise to remove and
catch escaping oil in a suitable container.

Dispose of the old oil filter and any used, accumulated oil according to
environmental care regulations!

 Clean the face of the combination block with a lint free cloth.
 Lightly oil the gasket of the new filter cartridge before screwing into position.
 Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.

Attention! Do not use a tool as this may cause damage to the oil filter cartridge
and the gasket.

 Check the oil level (see chapter 9.11).

 Close all maintenance doors and reattach all cover panels.
 Open the isolation shut ---off valve between the compressor and the compressed air
system.

Perform a test run

When the operating temperature is reached (see chapter 1.1), shut

down the compressor package (see chapter 8.4) and lock the main
disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the
compressor does not restart.

Afterwards, carry out a visual check for leaks.

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 Maintenance

9.11 Topping off the oil

The oil level indicator (9) of machines in operation should be checked weekly. The machine
should be topped off with oil as soon as the minimum level (1) (border of green and red) is
reached.

Attention! The machine may only be operated when the oil level indicator is in the
green zone.

low

high
low

high
1 2 3
low

high

1 Lowest oil level 2 Optimum oil level 3 Highest oil level

 Remove cover panel (3, siee chapter 9.2).

 Check the oil level when the compressor is running.
 Stop the compressor package under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.

 Venting the compressor package (see chapter 9.9).

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 Maintenance

10
A
1
B

2
8
3

5
7
4
6

9 a

c b

low

high
11
12
1 Ball valve 4 Filler plug 8 Maintenance hose (6 ---8)
A shut (oil top --- off) 9 Oil level indicator
B open 5 Oil separator tank 10 Hose coupling
2 Pressure gauge 6 Nozzle 11 Ball valve (oil drain)
3 Hose coupling 7 Ball valve 12 Hose coupling
9 Oil level indicator:
a) Optimum oil level (green zone)
b) Oil level too high (amber zone)
c) Oil level to low (red zone)
 Unscrew the oil filler plug (4) on the oil separator tank.
 Fill with oil up to the maximum indicator level. See chapter 1.7 for the oil volume
needed to increase the indicated level from minimum to maximum.
 Check the sealing ring of the filler plug (4) for damage and then replace the filler plug.
 Close all maintenance doors and reattach all cover panels.
 Open the isolation shut ---off valve between the compressor and the compressed air
system.
Attention! After an oil change or oil cooler cleaning (with removal of the oil
cooler) run the compressor package up to operating temperature to
ensure that the combination valve closes and that the oil cooler is
flooded with oil.

Afterwards, repeat the procedures ‘‘Venting the Compressor Package’’

(chapter 9.9) and “Topping off the Oil”
(chapter 9.11).

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 Maintenance

Attention! Always use the same brand and type of oil when topping off the oil.
(see label on the oil separator tank).

During an oil change, drain the old oil completely and always replace
the oil filter.

Never mix different oil types or brands.

Oil recommendations see chapter 1.8

9.12 Oil Change (Oil Separator Tank and Oil Cooler)

For type of oil and frequency of oil change see chapter 1.8

Oil change must be carried out with warm to the touch condition of the compressor pack-
age (Oil temperature approx. 104•F).

Danger of scalding with hot oil.

When inserting the maintenance hose into the compressor’s hose

couplings, always have the ball valve closed and the hose end se-
cured before slowly opening the ball valve. Beware of air/oil mist that
could blow out of the hose. Unrestricted air/oil flow through the hose
end will result in a whipping action which could cause severe injury or
death.

If the compressor package operates in ambient temperatures close to the maximum ambi-
ent temperature (see chapter 1.6), change the oil more often (e.g. 1/2 or 1/4 of recom-
mended interval).

Attention! Drain the oil out of the oil separator tank, cooler and the oil pipes com-
pletely. See chapter 9.12.4 for putting back into operation.

Attention! If a heat recovery system is fitted drain all the oil in the heat exchanger
during the oil change.

 Stop the compressor package under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.

 Venting the compressor package (see chapter 9.9).

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 Maintenance

10
A
1
B

2
8
3

5
7
4
6

9 a

c b

low

high
11
12
1 Ball valve 4 Filler plug 8 Maintenance hose (6 ---8)
A shut (oil top --- off) 9 Oil level indicator
B open 5 Oil separator tank 10 Hose coupling
2 Pressure gauge 6 Nozzle 11 Ball valve (oil drain)
3 Hose coupling 7 Ball valve 12 Hose coupling

 Open the cover panel (2 and 3, see chapter 9.2).

9.12.1 Oil change using external pressure source

Drain the oil from the oil separator tank:
 Close the ball valve (1).
 Insert the maintenance hose --- ball valve closed --- in the hose coupling (3) on the oil
separator tank (5).
 Connect the maintenance hose to external pressure source. Pressurize the oil separa-
tor tank (5) by slowly opening the ball valve (7) until the pressure gauge (2) on the oil
separator tank (5) shows approximately 43.5 psig.
 Remove the maintenance hose from the hose coupling (3) on the oil separator
tank (5).
 Prepare a clean container to catch escaping oil.

Attention! The container must be large enough to hold the total oil content of the
compressor unit (see chapter 1.7).

 Insert the maintenance hose --- ball valve closed --- in the hose coupling (12) on the
oil separator tank (5).

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 Maintenance

 Hang the maintenance hose into the container and secure.

 Open the oil drain valve (11).
 Slowly open the ball valve (7). The remaining pressure in the oil circulation forces out
the oil. When air escapes, close the ball valve (7) immediately.
 Close the oil drain valve (11).
 Disconnect the maintenance hose from the hose coupling (12).

Drain the oil from the oil cooler:

 Place the oil container under the oil cooler.
 Insert the maintenance hose --- ball valve closed --- in the hose coupling (5, chap-
ter 9.4) on the oil cooler.
 Hang the maintenance hose into the container and secure.
 Open the ball valve (4, see chapter 9.4).
 Slowly open the ball valve (7). The remaining pressure in the oil circulation forces out
the oil.
 Close the ball valve (4, see chapter 9.4).
 Remove the maintenance hose from the hose coupling (5, chapter 9.4) on the oil
cooler.

Dispose of the used oil according to environmental regulations.

 Open the ball valve (1).

9.12.2 Oil top -- off

Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.

 Venting the compressor package (see chapter 9.9).

 Unscrew the oil filler plug (4) on the oil separator tank.

Attention! Always use the same brand and type of oil when topping off the oil.
(see label on the oil separator tank).

During an oil change, drain the old oil completely and always replace
the oil filter.

Never mix different oil types or brands.

Oil recommendations see chapter 1.8

 Top off the oil to the maximum mark.

See chapter 1.7 for the quantity of oil.
 Check the gasket ring of the filler plug (4) for damage and then screw in the filler plug.
 Close all maintenance doors and reattach all cover panels.

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 Maintenance

9.12.3 Draining the oil using own compressed air

 Shut down the compressor unit under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures to ensure the compressor does
not restart.

Lock the isolation shut-- off valve in the ”closed” position and vent all
compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out proce-
dures.

The compressor unit oil circulation system vents automatically.

 Remove cover panel (3, siee chapter 9.2).
 The pressure gauge on the oil separator tank must indicate zero psig.
 Close the vent line ball valve (1).
 Close all maintenance doors and reattach all cover panels.
 Start the compressor package (see chapter 8.4) and allow to run for approximately 30
seconds.
 Stop the compressor package under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

 Open the cover panel (2 and 3, see chapter 9.2).

 Check the actual pressure on the pressure gauge (2). Open the shut ---off valve (1), let
the pressure on the pressure gauge (2) sink to approximately 40 psig and then close
the shut ---off valve (1) again.
 Drain the oil from the oil separator tank and the oil cooler. Proceed as detailed in chap-
ter 9.12.1).
 Open the shut ---off valve (1).
 Top off the oil. Proceed as detailed in chapter 9.12.2).
 Close all maintenance doors and reattach all cover panels.

9.12.4 Procedure for putting back into operation

 Refer to chapter 7.8.1 and follow the instructions in section ‘‘Pouring a small quantity
of oil into the air inlet port” .
 Refer to chapter 7.8.2 and followthe instructions in section ”Running the compressor
package in idle”.
 Refer to chapter 9.9 and follow the instructions in section ‘‘Venting the compressor
package”.
 Top off with oil again (see chapter 9.12.2).
 Open the shut ---off valve between the compressor package and the air system.
 Start the compressor package (see chapter 8.4) and run until working temperature is
reached (see chapter 1.1).
 Top off the oil, see chapter 9.11.

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 Maintenance

Perform a test run

When the operating temperature is reached (see chapter 1.1), shut

down the compressor package (see chapter 8.4) and lock the main
disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the
compressor does not restart.

Afterwards, carry out a visual check for leaks.

9.13 Changing the Oil Separator Cartridge

The service life of the oil separator cartridge is strongly influenced by the degree of conta-
mination of inlet air and on strict adherence to the recommended maintenance intervals of
the air and oil filters.
We recommend that the oil separator cartridge is changed with the oil or when the relevant
service message / alarm message is displayed on SIGMA CONTROL (see chapter 8.1).
 Stop the compressor package under full load (see chapter 8.4).

Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.

Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.

 Venting the compressor package (see chapter 9.9).

Attention! If the compressor package is positioned with its rear side against a
wall, the air filter should first be removed before attempting to change
the oil separator cartridge to give better access.

1 Screw
2 Air filter

 Remove cover panel (3, see chapter 9.2).

 Remove screws (1) and take off the air filter (2) with holder and lay aside.

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 Maintenance

19

16
20 21

20
23
21

20

20

14
17

25 15

14 Cover 16 Air pipe 20 Union nut

15 Dirt trap 17 Hexagonal screw 21 Gasket
(with copper pipe) 19 Self ---locking nut 23 Oil separator cartridge
25 Minimum pressure/check valve

 Remove cover panel (3, siee chapter 9.2).

 Loosen the union nuts (20) and lay the parts with connections carefully to the side ---
pull out the copper pipe at position (15).
 Unscrew the self locking nuts (19) on both ends of the air pipe (16).
 Withdraw the air pipe (16) from the minimum pressure/check valve (25) and push
carefully to one side.
 Unscrew the bolts (17) holding down the cover plate (14) and carefully remove the
cover plate.
 Remove the old oil separator cartridge (23), with gaskets (21).

Attention! When cleaning the sealing surfaces take care that no particles fall into
the oil separator tank.

The oil separator cartridge is a disposable item and cannot be

cleaned.

Dispose of the used oil separator cartridge according to environmental

regulation.

 Insert the new oil separator cartridge (23) with the new gaskets (21), fit and tighten
down the cover plate (14) with the bolts (17).
 Replace the strainer and the O---ring of the dirt trap (15) when the oil separator car-
tridge is replaced.
 Reassemble in the reverse order.
 Close all maintenance doors and reattach all cover panels.
 Open the isolation shut ---off valve between the compressor and the compressed air
system.

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 Maintenance

Perform a test run

When the operating temperature is reached (see chapter 1.1), shut

down the compressor package (see chapter 8.4) and lock the main
disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the
compressor does not restart.

Afterwards, carry out a visual check for leaks.

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 Maintenance

9.14 Maintenance Schedule

Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date Description of work Operating hours Signature

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 Spare Parts and After Sales Service

10 Spare Parts and After Sales Service

10.1 Service parts and maintenance parts

Description Qty. Order No.

Oil filter 1 6.3464.0

Air filter cartridge 1 6.3564.0

Filter mat 1 6.3572.0

Oil separator cartridge

Complete set 1 6.3571.0

Comprising:
Separator cartridge 1
Gasket 2
Dirt trap strainer 1
O---ring 1

Important for spare parts orders:

 Enter the data on the compressor name plate in the name plate shown above.
Always quote the data on the name plate when ordering spare parts.

Attention! Always order original spare parts from the compressor manufacturer
to avoid lower quality spare parts in your compressor unit.

10.2 Service and Maintenance Agreement

We recommend that you take out a service and maintenance agreement with an author-
ized KAESER distributor. This is your best guarantee of reliable air supplies.

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 Appendix

11 Appendix

11.1 Wiring Diagram

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 Appendix

11.2 Maintenance Schedule

Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date Description of work Operating hours Signature

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 Appendix

11.3 Trouble shooting: Possible cause ---Remedy

Attention! Do not attempt to carry out any repair until you are certain of its cause.

11.3.1 Airend temperature is too high (greater than 167•F-- 200•F)

Possible cause: Remedy:

Cooling air inlet or outlet is too close to Situate unit for adequate air flow.
wall or other blockage.
Air intake filter mats are clogged. Clean the mats or replace if necessary.
Ambient temperature is too high. Provide cooler air from other source or
move compressor to a cooler location.
See chapter 1.6.
Ambient temperature too low. Provide warmer air from other source
or move compressor to warmer loca-
tion or add a cabinet heater. See chap-
ter 1.6.
Cooling air supply is inadequate. Provide required amount of ventilation.
If cooling air outlet duct is used it may Consult authorized KAESER distributor
be too narrow or too long. for duct requirements.
On air cooled units the fins of the cool- Clean with compressed air, water or
ers (oil cooler and air aftercooler) are steam injector. See chapter 9.4.
clogged.
On water cooled units the heat ex- Inspect heat exchanger elements.
changer elements may be clogged. Clean or replace as necessary.
Oil level is low. Check oil level and add necessary
amount of recommended oil.
Check dirt trap strainer in oil return line
for possible contamination.
Thermostatic valve is not functioning Check the valve spring and actuating
correctly. piston. Replace defective parts.
Idle pressure is too low for proper oil Check idle pressure at the separator
circulation. tank. If the pressure is low check the
inlet valve. Adjust inlet valve to main-
tain adequate idle pressure.
Wrong oil is used. Drain old oil completely and replace
with recommended type.
Consult authorized KAESER distributor
for other oil types not listed.
Oil filter is clogged. Replace filter.
Airend is defective. Check airend and replace if defective.

11.3.2 Motor overload relay switches the unit off

Possible cause: Remedy:

Overload relay is defective or setting is Check line current and adjust overload
wrong. relay as necessary.
Replace relay if defective.

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 Appendix

Possible cause: Remedy:

Motor is running two phase: defective Check input power, check wiring, tigh-
motor or blown fuse. ten any loose connections.
Replace fuse(s) or motor if necessary.
Oil separator cartridge is contamina- Check pressure differential across car-
ted. tridge. Replace cartridge and dirt trap
strainer if necessary.
Motor starts against pressure because Check ball valve in vent line and open
system does not get vented. if it is closed.
Check the diaphragm in the vent valve
and replace if defective.
Check the minimum pressure check
valve. Adjust minimum pressure func-
tion or replace defective parts as ne-
cessary.
Airend is defective. Check airend and replace if defective.
Ambient temperature is above 104•F. Provide adequate compressor ventila-
tion.
Defective motor: bad bearings or short Repair or replace motor.
circuit in windings.

11.3.3 Compressor is running but produces no pressure

Possible cause: Remedy:

Airend rotates in wrong direction. Reverse motor polarity.
Inlet valve does not open or opens Check the inlet valve, control valve and
only partially. lines. Replace defective parts as
needed
Vent valve does not close at full load. Check the combined control/vent valve
and control lines. Replace defective
parts as needed.
Minimum pressure check valve is de- Check the valve and replace defective
fective. parts.
Leaks in plant system. Check for open valves, loose connec-
tions, defective tools, etc.
Plant system air, demand exceeds ca- Reduce system demand or install
pacity of compressor additional compressor(s).
Air leak in unit. Tighten loose connections, repair or
replace defective parts as necessary.
Socket is still in the hose coupling at Remove socket from coupling.
the oil separator tank or aftercooler.
Safety relief valve has blown off. See chapter 11.3.5.
Airend is defective. With unit running, slowly and carefully
place hand over air inlet filter casing.
There should be considerable suction.
If not, airend is producing no pressure.

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 Appendix

11.3.4 Oil leaks out of air filter

Possible cause: Remedy:

Oil level in separator tank is too high. Drain oil to correct level.
Inlet valve faulty. Find the fault and replace the defective
part.

11.3.5 Full -- load/Idle sequence occurs too frequently (short cycles)

Possible cause: Remedy:

Receiver tank size is too small or there Consult authorized KAESER distributor
is no tank. for recommended tank size.
Diameter of hose connecting the unit Connecting hose diameter should not
to the receiver tank is too small. be smaller than the air discharge pipe
diameter. Install larger hose if neces-
sary.
Minimum pressure check valve leaks. Check the valve and replace defective
parts.
Flow is restricted at discharge. Look for plugged filters, partially
closed valves, frozen pipes or malfunc-
tioning pressure regulators.

11.3.6 Safety relief valve blows off

Possible cause: Remedy:

System does not discharge at idle. Make sure ball valve in vent line is
open. Check the control lines, inlet
valve and combined control/vent valve.
Replace defective parts as needed.
Oil separator cartridge is contamina- Check the cartridge pressure differen-
ted. tial and replace cartridge if necessary.
Minimum pressure check valve does Check the valve for blockage and re-
not open. place defective parts as necessary.
Safety relief valve not properly sized Check blow ---off pressure and com-
for the pressure of the compressor pare to name plate of the compressor.
unit. Replace if necessary.

11.3.7 Oil inside the unit

Possible cause: Remedy:

Socket is still in the hose coupling at Remove the socket from the coupling.
the separator tank.
Safety valve has blown off. See chapter 11.3.5.
Oil is coming out of air filter. See chapter 11.3.4.
Hose coupling on separator tank is Tighten coupling or replace as
loose. needed.
Oil cooler leaks. Replace oil cooler.

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11.3.8 Excessive oil consumption

Possible cause: Remedy:

Wrong oil is being used in the unit. Replace with correct oil type.
Consult authorized KAESER distributor
for other oil types not listed.
Oil separator cartridge has ruptured. Check pressure differential and re-
place oil separator cartridge if neces-
sary.
Oil separator cartridge mountings are Tighten mounting bolts.
loose.
Oil level in separator tank is too high. Drain oil to correct level.
Scavenger line is clogged. Inspect dirt trap strainer in scavenger
line. Clean or replace clogged parts as
necessary.

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