SERVICE MANUAL E

Screw compressor –
Refrigeration dryer – Combination
Model: AIRTOWER 26 / 10 bar
GL-Nr.: 1_8840_20290-00 06

Table of contents:

Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . for Part of Unit

P&I-Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airtower

Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airtower
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw compressor
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration dryer
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Condensate Drain

Part No.:
Serial No.:

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49 – 9561 – 6400 • Fax +49 – 9561 – 640130
http://www.kaeser.com
A 0 bar/psig!

B
0 bar/psig!
1
SERVICE MANUAL E

Screw Compressor
Model: SK 26 / 10 bar
GL---Nr.: 1_9764_50261---00 02

Part No.: ...............................................

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

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg ! PO Box 2143 ! GERMANY ! Tel. + 49---(0)9561---6400 ! Fax + 49---(0)9561---640130
http://www.kaeser.com
 Table of Contents
Chapter --- Page

1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.5 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Recommended cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.10 Compatibility of KAESER cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 4
1.11 Maintenance Interval for the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 4
1.12 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 4

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.2 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 6
2.3 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.4 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.5 Compressed Air Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.6 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.2 Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.3 Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.5 Accompanying Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12

5 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.2 Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.3 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 5 --- 13
5.4 DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 16
5.5 QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 17
5.6 VARIO Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

i
 Table of Contents
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7 Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 21

7.1 Points to be Noted before Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 21
7.2 Observe the following before starting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 21
7.3 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.4 Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 24
7.5 Setting up the Motor Overload Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 24
7.6 Setting the Air Main Pressure Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.7 Door Interlock Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.8 Measures to be taken before Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
7.8.1 Pour a small quantity of oil into the air inlet port. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
7.8.2 Running the compressor package in idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.2 SIGMA controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.2.1 Emergency Stop Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.2.2 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.2.3 Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.3 Compressor Package ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.4 Acknowledgement of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.5 Acknowledgement of Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 31
8.6 Faults: Possible cause --- Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 32
8.6.1 Working temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 32
8.6.2 Motor overload protection relay trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 32
8.6.3 Compressor runs but does not reach pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.6.4 Oil running out of air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 33
8.6.5 Too frequent switching between load and idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.6.6 Pressure relief valve blowing off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.6.7 Oil in the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34
8.6.8 Cooling fluid consumption too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 34

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.1 Observe the following during all maintenance and servicing. . . . . . . . . . . . . . . . 9 --- 36
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 37
9.3 Opening and Closing the Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.4 Checking the Tension of the V---belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.5 Changing the V belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.6 Cleaning or Renewing the Filter Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.7 Cleaning or Renewing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.8 Servicing the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41
9.9 Checking the Pressure Relief Valve on the Oil Separator Tank . . . . . . . . . . . . . . 9 --- 41
9.10 Venting the Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 42
9.11 Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.11.1 Removal and replacement of the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.12 Topping up the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 44
9.13 Cleaning the Oil Cooler and Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46

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 Table of Contents
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9.13.1 Removing and cleaning the oil/air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46

9.14 Oil Change (Oil Separator and Oil Cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.14.1 Draining the oil using external pressure source . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.14.2 Adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.14.3 Draining the oil using own compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
9.14.4 Measures for putting back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 50
9.15 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 51
9.16 Record of Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 53

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54

10.1 Service parts and expendable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 54
10.2 Service and Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 55

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 56
11.1 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 56
11.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 73

iii
 Technical Specification

1 Technical Specification

1.1 Compressor Package

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK 26
Permissible gauge working pressure . . . . . . . . . . . . . . . . . . . . 10 bar
Operating temperature, approx. . . . . . . . . . . . . . . . . . . 75 --- 100 "C
(related to the gauge working pressure and climatic conditions
such as humidity in the air and ambient temperature).
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 kg

Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . T7471.05
P & I flow diagram . . . . . . . . . . . . . . . . . . . FSK26STL---00023.00
(Pipework and instrument flow diagram)
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . SSK26---01027.01

1.2 Sound Pressure Level

Operational state of the compressor unit:
Full load, the compressor unit runs at: rated speed, rated pressure, rated capacity.
Setting up conditions:
Free field measurement
Measurement to CAGI/PNEUROP PN8 NTC 2.3:
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 dB (A)

1.3 Motor
Drive motor:
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 kW
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 min ---1
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP 54

1 --- 1
 Technical Specification

1.4 Power Supply

(see chapter 6.3 for further details)
Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 V 3!/PE
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Max. mains fusing (slowblow or gl class) . . . . . . . . . . . . . . . . 35 A
Power supply cable cross---section . . . . . . . . . . . . . . . . . . . . 4 x 6 mm2
(CU multicore cable)
Current flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 A

1.5 Pressure Relief Valve

Activating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,5 bar

1.6 Installation Requirements

Max. height above sea level . . . . . . . . . . . . . . . . . . . . . . . . . 1000 m
(consult with the manufacturer before installing at greater altitudes)
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 "C
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 "C
Min. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . . . 3 "C
Max. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . . 40 "C
Air inlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 m2
Exhaust air for solution A (see chapter 6.1):
Forced ventilation with exhaust fan . . . . . . . . . . . . . . . . . . . . 4000 m3/h at 100 Pa
Exhaust air for solution B (see chapter 6.1):
Exhaust air used for space heating:
Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 x 510 mm

1.7 Oil Capacities

Total oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 l

After oil change or after long period of storage

Amount required to top up the airend . . . . . . . . . . . . . . . . . . 0,5 l

1 --- 2
 Technical Specification

1.8 Cooling oil changing intervals

The duty cycle and ambient conditions are important criteria for the number and length of
the change intervals.

Cooling oil Maximum permissible oil change interval

[operating hours / year]
Favourable operating Unfavourable operating
conditions* conditions
SIGMA FLUID PLUS / S---460 6 000* * / 2 3 000 / 1
SIGMA FLUID MOL 3 000 / 1 2 000 / 1
SIGMA FLUID FGL 3 000 / 1 2 000 / 1
SIGMA FLUID FGH 3 000 / 1 2 000 / 1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
* * Changing intervals > 6000 operating hours, permissible only with oil analysis. More
information obtainable from KAESER Service.

1.9 Recommended cooling oil

A sticker showing the type of oil filled is to be found near the oil separator filling port.

SIGMA SIGMA SIGMA

FLUID PLUS / S-- 460 FLUID MOL FLUID FGL / FGH
Description Synthetic oil Mineral oil Synthetic oil
Application: Standard oil for all ap- Standard oil for all Specially for use in
plications except in applications except compressors where
connection with foods- in connection with the air comes in direct
tuff. foodstuff. contact with foodstuff.
Designed for high load- Designed for light
ing and long oper- loading.
ational life.
Authorization — — USDA H–1, NSF
Approved for the
manufacture of foods-
tuff packaging, meat
and poultry proces-
sing and other food
processing.
Viscosity at 70 mm2/s 44 mm2/s 50.7 / 70 mm2/s
40 !C (DIN 51562---1) / (DIN 51562---1) (D 445; ASTM test)
43.8 mm2/s
(D 445; ASTM test)
Viscosity at 10.6 mm2/s 6.8 mm2/s 8.2 / 10.4 mm2/s
100 !C (DIN 51562---1) / (DIN 51562---1) (D 445; ASTM test)
6.9 mm2/s
(D 445; ASTM test)
Flash point 260 !C (ISO 2592) / 220 !C 254 !C
238 !C (ISO 2592) (D92; ASTM test)
(D 92; ASTM test)
Density at 15 !C 843 / 864 kg/m3 — —
(ISO 12185)

1 --- 3
 Technical Specification

SIGMA SIGMA SIGMA

FLUID PLUS / S-- 460 FLUID MOL FLUID FGL / FGH
Pour point ---39 !C ---33 !C —
(ISO 3016) / (ISO 3016)
---46 !C
(D 97; ASTM test)
Demulsibility at 30 min — —
54 !C (ISO 6614) /
40/40/0/10 min
(D1401; ASTM---Test)

1.10 Compatibility of KAESER cooling fluid

All the KAESER cooling fluids mentioned above are comparable with mineral oil with regard
to their material compatibility with paints, sealants and hoses.

Attention! Never mix different types of cooling fluid!

Synthetic cooling fluids can attack polycarbonate oil trays. For this
reason, we recommend metal oil trays.

Certain plastic parts in the compressed air supply may not be resistant
to synthetic cooling fluid.

When changing the type of cooling fluid, ensure that the fluid circulation system of the
compressor package is completely drained before filling with the new fluid. As far as poss-
ible, remove any deposits in the cooling system.
It is possible that the separator cartridge will have to be changed because of existing cool-
ing fluid deposits that detach themselves after changing the type of cooling fluid. This
one---off, additional requirement is caused by the cleaning effect of the new cooling fluid.

1.11 Maintenance Interval for the Electric Motor

Renew the compressor motor bearing:
Under normal operating conditions, after . . . . . . . . . . . . . 12000 h*
(ambient temperature up to 25"C)
Under unsuitable operating conditions, after . . . . . . . . . . . 6000 h*
(ambient temperature up to 40"C)
at the latest after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 years
* service hours

1.12 Dimensional Drawing

(see following page)

1 --- 4
Technical Specification

1 --- 5
 Safety

2 Safety Regulations

Disregarding this notice can result in serious injury!

This manual should be read and the instructions it contains followed before initial start ---up
and before carrying out maintenance work.

2.1 Explanation of Symbols and References

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

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 package and/or other equipment is prevented.

This symbol identifies environmental protection measures.

! This symbol indicates operations to be carried out by the user.

" This bullet identifies listings.

Explanation of warning labels:

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

Beware of high voltage. Do not touch electrical components; danger of

electric shock.

Beware! Machine starts automatically. Machine can start automatically

or by remote start command.

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

2.2 Safety Notes

Work on power-- driven equipment may only be carried out or super-
vised by persons trained in that particular equipment or by a special-
ist.

Work on electrical equipment in the compressor may only be carried

out according to electrical engineering regulations by a qualified elec-
trician, or trained personnel under the supervision of a qualified elec-
trician.

2 --- 6
 Safety

Before work is carried out on electrical systems, carry out the follow-
ing measures in the sequence shown:

Switch off all phases.

Ensure the unit cannot be switched on again.

Check that no voltage is present.

The following actions must be carried out in the order given before
working on any pressurised parts or enclosures (e.g. pipes, vessels,
valves).

1. Shut off and depressurize all pressurized components and enclos-

ures

2. Secure them in the depressurized state

3. Check that they are indeed de -- pressurized

Attention! Any alterations or reconstruction carried out without consultation with

and the previous consent of KAESER COMPRESSORS will invalidate
the warranty.

Attention! No welding, heat-- treatment or mechanical modifications may be car-

ried out on pressurised components such as. pipework, air receivers,
etc.

Attention! Safety devices may not be modified or deactivated.

Signs and marks of reference may not be removed or rendered unre-

adable.

The relevant statutory regulations must be observed during installation, operation, mainten-
ance and repair of the compressor package.
These are, for example, nationally applied European directives and / or valid national laws,
safety and accident prevention regulations.
These instructions must also be observed:
" Allow no open flames and flying sparks at the place of installation.
" Ensure that sparks or high temperatures cannot cause fire or explosion if welding is
carried out on or near the compressor.
" Ensure that the compressor unit can breathe clean intake air that contains no damag-
ing components.
" Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
otherwise special measures must be agreed between the manufacturer and the cus-
tomer.
" Carry out oil changes according to the service manual.
" Use only oils recommended by the manufacturer.
" Do not mix cooling oils of different types.
" The operating temperature stipulated must be kept to and checked constantly to avoid
condensate in the oil circulation.

2 --- 7
 Safety

" If maintenance work is carried out on any part of the oil circulation system, top up the
oil in the oil separator tank to the maximum level afterwards, run the compressor for a
short period and keep it under constant observation. Check the oil level again and top
up with oil to replace the oil taken up by the piping and the cooling system.
" Use the filter cartridge of the oil separator tank only as long as the pressure drop
across the filter is less than the 1 bar specified. Check constantly.
" This machine is not explosion ---proof.
It may not be operated in areas in which specific requirements with regard to ex-
plosion protection are applied.
These are, for example, the requirements for “specified use in hazardous explosive
environments” according to the 94/9/EU ATEX Directive.

2.3 Electrical Safety

The electrical installation of the compressor package must conform to the requirements of
European Standards EN 1012---1 and EN 60204---1. The regulations of the local electricity
authority must also be complied with.
For this reason, the following measures must be carried out by the user to ensure the
safe operation of the compressor package:
" Compressor packages fitted with a drive motor of 3 kW or above and a current rating
of 16 amperes or above must be fitted with with a lockable main switch (see EN
60204---1, P 5.3) and mains fuses.
" The type of main switch used is dependent on the power consumption of the drive
motor (see chapter 1.4 for value).
" The type of protective circuit breaker used is dependent on the starting characteristic
of the drive motor.
" See chapter 1.4 for recommended cable cross---sections and fuses.

2.4 Spare Parts

Genuine KAESER parts are designed and matched to meet the technical requirements of
the compressor package.
This means that safe and reliable operation of the compressor package can only be guar-
anteed if genuine KAESER spare parts and KAESER SIGMA FLUID is used.

Attention! Use only original parts in assemblies subject to pressure.

2.5 Compressed Air Installation

If a compressed air installation is extended or changed, check the blowoff pressure of the
pressure relief valves on the air receiver tanks and in the pipework before the new com-
pressor package is installed.
If the blowoff pressure is too low, fit a pressure relief valve with correspondingly higher
blowoff pressure.

2 --- 8
 Safety

2.6 Environmental Protection

Condensate drainage

The condensate accumulating during compression must be fed via a

suitable drainage system into special canisters and disposed of ac-
cording to environmental regulations.

Lubricants / consumable materials / replacement parts

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.

The following points must be observed when handling lubricating and

cooling materials:

Avoid contact with skin and eyes.

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

2 --- 9
 General

3 General

The service manual must always be available for use at the location of
the compressor package.
The right is reserved to make technical changes and improvements to equipment which
may then result in discrepencies in the details of that equipment contained in this manual.

3.1 Correct use

The compressor package is intended solely for the purpose of generating compressed air.
Any other use is considered incorrect. The manufacturer cannot accept liability for any
consequential damage caused by such incorrect use; the user alone is liable for any risks
incurred.Correct use of the compressor also encompasses adherence to the installation,
dismantling, commissioning, operational and maintenance conditions laid down by the
manufacturer.
This compressor package may only be used for industrial purposes.
If the compressor package is operated in an air distribution network, the maximum network
pressure may not exceed 16 bar.

Attention! The equipment may only be used or serviced by persons who are au-
thorised and trained.

3.2 Incorrect Use

Never direct compressed air toward any person at any time. As it
represents contained energy, it is dangerous to life.

Attention! Inlet air may not contain any explosive or chemically unstable gas or
vapour.

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
All rights reserved.
No part of this publication may be reproduced or utilized in any form or by any means,
electronic or mechanical, including photocopying and microfilm, without prior permission in
writing from KAESER COMPRESSORS.

3.5 Accompanying Documents

With this Service Manual are documents intended to assist in safe and sure operation of
the compressor:
# Certificate of acceptance / operating instructions for the pressure vessel
# Conformity or Manufacturer’s Declaration in accordance with applicable directives
$ Make sure all documents are to hand and their contents understood.
Request the supply of any missing documents from KAESER.
Make sure you give the data from the nameplate.

3 --- 10
 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. 1000 mm

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

4.2 Packaging
Always observe the instructions in chapter 4.3 when packaging the machine for storage.
Use packaging suitable for the intended route if the machine is to be transported further by
the customer.
Overland
The machine should be protected from mechanical damage by a sturdy crate and from
moisture by plastic sheeting.
By sea or air
Special packaging instructions can be obtained from KAESER.

Dispose of the packaging according to environmental regulations and

recycle where possible.

4 --- 11
 Transport

4.3 Storage
If the equipment is to stand idle for a long period the prescribed measures must be taken
to avoid damage.
If any measures can not be taken, advice should be sought from the authorised KAESER
Service depot.

Attention! Basically, the equipment should be stored in a dry, frost-- free room.
Protect against ingress of moisture or formation of condensation.
See chapter 7.8 for instructions on start-- up.

Storage up to 6 months (temporarily out of service):

As an alternative to storage, the equipment can be run once a week for 30 minutes at op-
erating temperature to ensure adequate corrosion protection.
Otherwise, the measures described under “’Storage for longer than 6 months’ are to be
taken.

Storage for longer than 6 months:

Ensure the equipment is dry and cover in plastic sheeting. Protect the interior with suffi-
cient quantities of desiccant (silica gel or similar).
Storage for longer than 12 months:
Carry out the following additional maintenance tasks before putting into operation:
$ Change the cooling fluid filter (see chapter 9.11).
$ Change the fluid separator cartridge(see chapter 9.15).
$ Change the cooling fluid (see chapter 9.14).
$ Have the motor bearings checked by an authorised KAESER service technician.
Storage for longer than 3 years:
After 3 years at the latest the complete technical condition of the equipment must be
checked before start ---up.

Attention! Starting up the equipment without a full inspection can lead to dam-
age.

$ Have the the start ---up carried out by an authorised KAESER service technician.

4 --- 12
 Construction and Operation

5 Technical Description

5.1 Principle of Compression

The stationary compressor package is fitted with a single stage, oil---injected airend. Two
rotors, the driven male rotor and the female rotor, both mounted in roller bearings, are
fitted in 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 ab-
sorbs heat generated by compression, prevents metallic contact between the rotors, seals
the rotors and the housing from each other and also lubricates the roller bearings. The
compressed air and oil mixture leaves the airend via the discharge port.

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

5.2 Short Description

The compressor block is driven via V---belts from an electric motor.
An oil separator cartridge is fitted into the oil separator tank allowing practically oil free
compressed air supply.
The regulation of the compressor package ensures that compressed air is generated
within set pressure limits.
A safety function protects the compressor package against failure of important systems
through automatic shut ---down.
The fan ensures ventilation of the compressor package and also sufficient cooling air for
the air---cooled oil and air cooler.

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

(see following pages)

5 --- 13
Construction and Operation

5 --- 14
Construction and Operation

5 --- 15
 Construction and Operation

5.4 DUAL Control

p
max
Pressure

p
min

1 2 3 4 5
Full load t1 t2
Motor power

Idle
Standstill
Time
In DUAL Control mode (combined idle and start ---stop) the compressor normally runs at
full -- load, idle or standstill.
The controller regulates the compressor package between 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 load.
The idle period is dependent on the maximum motor starting frequency.

5 --- 16
 Construction and Operation

5.5 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 main pressure rises
from the lower to the upper switching point)
tp decay pressure decay time (the time during which the air main 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 main
pressure reaches the upper switching point. These two periods are set according to the
maximum permissible starting frequency of the drive motor.
The running period starts every time the compressor package is switched on. It lasts as
long as the drive motor runs and stops when the compressor package switches to stand-
still.
The idle/standstill period starts every time the operating mode changes from full load to
idle. 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 main pressure decays to the lower switching point, the compressor package
switches to full load (1) irrespective of its previous operating mode. If the drive motor
was at a standstill the opening of the inlet valve is delayed to allow an unloaded com-
pressor package start.

5 --- 17
 Construction and Operation

# If the air main 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 main 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 package is switched to standstill after the run ---on period has
expired (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).

5.6 VARIO Control Mode

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.

5 --- 18
 Installation

6 Installation

6.1 Installation Requirements

Attention! Ensure that the compressor package is level.
The floor must be solid with good loading characteristics.
See chapter 1.1 for the weight of the compressor package.
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 package 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 package as detailed in the following diagram. Keep to the minimum
distances 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.

Exhaust ventilator
Exhaust

min. 2200
A
duct

B
1017

h Air inlet
opening

800 784

A
500

B
b
820

min. 2200

min.
550

900
min. 2200
Measurements in mm

Solution A: forced ventilation

The exhaust fan fitted in the compressor space must provide adequate ventilation relative
to the size of the compressor package (see chapter 1.6).

6 --- 19
 Installation

Solution B: exhaust air used for space heating

The hot air is forced through a duct into the room to be heated.

Attention! The choice of exhaust air ducting, length of ducting and number
of bends can affect the compressor cooling system and must be
approved by the manufacturer.

Reliable, safe operation of the compressor package is only warranted if the temperature
limits (see chapter 1.6) of the air in the compressor space are kept to.

6.2 Connection of the Compressed Air Supply

The unit is set up ready to operate. Connect the discharge outlet to the user pipework
using a flexible connection hose.

6.3 Electrical Connection

The connection to the main power supply and the protective measures
required are to be carried out by an authorized electrician to the re-
quirements of European Standard EN 1012 -- 1 and EN 60204 -- 1 and to
the regulations of the local electricity authority.

The compressor package is wired ready for connection to the main power supply as de-
tailed in the electrical diagram.

Attention! The user of a compressor is obliged to carry out the following

measures:

Compressor packages fitted with a drive motor greater than 3 kW and

a current rating greater than 16 ampere must be installed with a lock-
able main isolating switch and main fuses.

The type of main switch used is dependent on the power consumption

of the drive motor (see chapter 1.4 for the value).

The type of protective power circuit breaker used is dependent on the

starting characteristic of the drive motor.

Attention! The cross-- section of the supply cable and the fuse ratings are speci-
fied to DIN VDE 0100 part 430 and 523 for an ambient temperature of
30 !C. For other operating conditions, e.g. higher ambient tempera-
tures or longer supply lines (over 50 m) check and determine the
cross-- section of the cable and the fuse ratings according to
DIN VDE 0100 and local electricity authority regulations.

See chapter 1.4 for recommended cable cross-- sections and fuses.

6 --- 20
 Initial Start

7 Initial Start---up

7.1 Points to be Noted before Initial Start---up

Every compressor is given a test run in the factory and carefully checked before shipment.
The test run confirms that the compressor conforms to specifications and runs perfectly.
However, independent of the checks made at the factory, the compressor could be dam-
aged during transport. For this reason, we recommend that the compressor package is
examined for such possible damage. 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, pressure relief valve, inlet valve and
combination valve) are adjusted and fitted in the factory to precise set-
ting up regulations. Alterations to these components are not allowed
without previous consultation with the manufacturer.

The minimum pressure/check valve, pressure relief valve and inlet

valve are spring biased.
There is considerable danger of injury through the release of the
spring when these components are opened.

7.2 Observe the following before starting:

NON -- OBSERVANCE OF THESE OR OTHER INSTRUCTIONS (WARN-
ING; ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO
PERSONNEL OR DAMAGE TO EQUIPMENT.

The compressor starts automatically again when power returns after a

power failure (standard setting).
This is conditional on system pressure being lower than the pressure
setpoint (cut-- out pressure) on SIGMA CONTROL.

Operation of the compressor with inspection doors open or cover pan-

els removed is strictly forbidden, as injury can result from rotating
parts or electrical components.

! Remove all packing materials, tools and transport devices on and in the machine.
" It is expected that safe working methods are used and that all locally applicable oper-
ational and safety regulations are complied with.
" The user is responsible for the safe operating condition of the compressor package.
" Do not operate this compressor package in environments where the air is heavily con-
taminated with dust or where toxic or inflammable gases may be present.
" Do not connect the compressor package to a power supply different to that shown on
the nameplate.
" Do not install the compressor package in an environment subject to freezing tempera-
tures. The air temperature specified for the air---intake must be kept to (see chapter
1.6).
" If exhaust ducting is fitted, it must have a cross sectional area at least equal to the
cooling air outlet on the compressor package itself, and may not create a pressure
drop greater than that specified by the compressor manufacturer.

7 --- 21
 Initial Start

" The compressor must be positioned with its cooling air inlet opening at least 1 m from
any wall.
! Check the cooling fluid level in the fluid separator tank (see chapter 9.12).
" The airend shaft must rotate in the correct direction (see chapter 7.4).
! Check the tension of the V---belts (see chapter 9.4).
! The shut ---off valve (6.6, see chapter 5.3) must be closed.
! The shut ---off valve (20, see chapter 5.3) must be open.

Carry out the following work only when power is removed from the
compressor package.

Check all screws on the electrical connections for tightness (carry out
this check again after 50 operating hours).

" This compressor package is fitted with a running ---in oil filter. Replace the filter after the
running ---in period of 200 hours has elapsed (see chapter 9.11).

7 --- 22
 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 air main?
# 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 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

7 --- 23
 Initial Start

7.4 Direction of Rotation Check

Attention! The compressor package is wired for connection to a clockwise phase
sequence.

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 air end hous-
ing.
If the direction of rotation is incorrect, change over the supply conductors L1 and L2.

Attention! If the air end rotates in the wrong direction, the compressor package is
automatically shut down by the pressure switch (4.2, see chapter 5.3).

7.5 Setting up the Motor Overload Trip

Disconnect the supply voltage to the compressor package by switch-
ing off and locking out the main switch before any adjustments are
carried out on the compressor package. See chapter 2.3 for the main
switch.

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

Compressor motor: star-- delta start

In the star---delta configuration the phase current is fed via the motor overload trip. This
phase current is 0.58 times the rated motor current.
See motor nameplate for the rated motor current.

Value:
To prevent the overload circuit breaker from triggering (because of voltage fluctuations,
temperature influences or component tolerances), the set value can be up to 15% higher
than the arithmetical phase current.

1 Motor phase current adjustment

2 Reset button

7 --- 24
 Initial Start

7.6 Setting the Air Main Pressure Threshold

The air main pressure threshold 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.

Attention! Switching from full load to idle running may take place no more fre-
quently than 2 times per minute.

Switching frequency can be improved by increasing the difference between cut ---in and
cut ---out pressure.
In addition, a larger air receiver can be installed to increase buffer capacity.

7.7 Door Interlock Switch Check

It is not permitted to operate the compressor package without a cor-
rectly functioning door interlock switch.

1 Door interlock switch

Visual door interlock switch check

! Check that the interlock switch operates smoothly by opening and closing the left ---
hand access door.

Attention! If the actuator (3) at the door interlock is incorrectly aligned, inadver-
tent shutdown of the compressor package can occur.

The actuator (3) should align with the door interlock switch (1) without
binding against the sides of the interlock switch when the access door
is closed.

If necessary, re---align the actuator (3).

! Loosen the bolts (4).
! Align the actuator (3) so that it glides smoothly into the interlock switch (1).

7 --- 25
 Initial Start

! If necessary, use shims to help align the actuator (3) with the interlock switch (1).
! Tighten the bolts (4) again.

2
3

4
4

1 Door interlock switch 4 Bolt

2 Clamping nut 5 Frame
3 Actuating element 6 Access door

Functional check of the interlock switch

Attention! A functional check of the door interlock switch must be made after in-
itial start.

! Start the compressor package (see chapter 8.3).

! Open the left ---hand access door --- the compressor package will shut down immedi-
ately if the door interlock switch functions correctly.
! Close the left ---hand access door.
! Reset the alarm message by pressing the acknowledge (reset) key (11, see
chapter 8.2.2) on SIGMA CONTROL.
The compressor package is now ready to start again.

7.8 Measures to be taken before Initial Start

Take the following measures before initial start, after an oil change or a shutdown period of
three months or longer:

7.8.1 Pour a small quantity of oil into the air inlet port.

Switch off and lock out the main switch.

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

See chapter 9.10 to vent the compressor.

7 --- 26
 Initial Start

! Unscrew the filler plug (1) on the inlet valve (2) and pour the prescribed quantity of oil
(see chapter 1.7) into the airend.
! Turn the airend counterclockwise by hand using the belt pulley.
! Screw the plug back in again.

Attention! This oil must be of the same type as used to run the compressor (see
label near the oil filler plug on the oil separator tank).

If no additional oil is available then remove the required amount of oil

from the oil separator tank. See chapter 9.14 for this procedure.

If the compressor package was shut down for longer than 12 months,
further measures must be taken before putting it back into operation.
Consult the manufacturer first.

! Open the shut ---off valve between the compressor package and the air main.

1 Filler plug
2 Inlet valve

7.8.2 Running the compressor package in idle

At initial start run the compressor package in idle for 20 seconds by pressing the load/idle
key (5, see chapter 8.2.2).
This measure ensures that the compressor package has sufficient time to flood the oil cir-
culation.

7 --- 27
 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.

8.2.1 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 8.2.2.)

8 --- 28
 Operation

8.2.2 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

8.2.3 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

8 --- 29
 Operation

8.3 Compressor Package ON/OFF

Attention! Do not switch the the compressor package on and off with the main
switch. The compressor must always be switched ON and OFF with
keys (1) and (2).

Local ON:
! Switch on the main 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.

Local OFF:
! Press the OFF key (2) --- LED (19) extinguishes.
! Switch off and lock out the main switch.
See chapter 2.3 for details of the main switch.

8.4 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.

8 --- 30
 Operation

8.5 Acknowledgement of Service Messages

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

8 --- 31
 Operation

8.6 Faults: Possible cause --- Remedy

The removal of faults that are not explicitly described in this service
manual may only be carried out by KAESER or by an authorised
KAESER service agency.

8.6.1 Working temperature too high

Possible cause: Remedy:

The distance from the cooling air inlet Keep to the minimum distance and en-
or outlet is too small. sure sufficient ventilation.
Insufficient cooling air flow. Ensure sufficient ventilation.
Ambient temperature too high. Arrange for a supply of cooler air or
move the machine to a cooler place
(see chapter 1.6).
If ducting is used for cooling air dis- Have an authorised KAESER service
charge it could be too narrow or too agent install adequately sized ducting.
long.
If the machine is air---cooled, the fluid/ Clean the fluid/air cooler (see chapter
air cooler could be clogged. 9.13).
If the machine is water---cooled, the Have an authorised KAESER service
heat exchanger could be clogged by agent inspect, clean or replace the
deposits. heat exchanger as necessary.
Air inlet filter mats clogged. Clean or replace the filter mats.
Fluid level too low. Top up to the correct level with recom-
mended cooling fluid.
Check and clean the dirt trap strainer
in the fluid scavenge line.
Thermostatic valve not functioning cor- Check valve spring and activating pis-
rectly. ton. Replace defective parts.
Wrong cooling fluid used. Drain off old cooling fluid and replace
with recommended type.
Ask an authorized KAESER service
agent for recommendations on cooling
fluid types.
Fluid filter clogged. Change the fluid filter (see chapter
9.11).
Airend defective. Have the airend checked by an autho-
rised KAESER service agent.

8.6.2 Motor overload protection relay trips

Possible cause: Remedy:

Protection relay is defective or incor- Check the wiring and reset the relay if
rectly set. necessary.
Replace a defective overload relay.
Motor runs on two phases; motor de- Check power supply and wiring.
fective or one of the customer’s fuses
blown.
Change fuse(s) or motor as necessary.

8 --- 32
 Operation

Possible cause: Remedy:

Oil separator cartridge clogged. Check pressure drop over the oil sepa-
rator cartridge. If necessary, change oil
separator cartridge and dirt trap sieve.
Motor starts against pressure as the Check that the vent line ball valve is
compressor has not vented. open.
Check the venting valve diaphragm
and change if necessary.
Have the minimum pressure/check
valve inspected by an authorized KAE-
SER Service Technician.
Airend defective. Have the airend inspected by an au-
thorized KAESER Service Technician.
Ambient temperature too high. Arrange a supply of cooler air or move
the machine to a cooler place (see
chapter 1.6)
Motor defective; bearing damage or Have the motor repaired or replaced
winding short by an authorized KAESER Service
Centre.

8.6.3 Compressor runs but does not reach pressure.

Possible cause: Remedy:

Motor turning in the wrong direction. Check motor connections.
Inlet valve not opening or only opening Have the valve inspected by an autho-
partially. rized KAESER Service Technician.
Venting valve not closing under full Check the combination control/venting
load. valve and lines and pipework.
Replace defective parts.
Minimum pressure/check valve defec- Have the valve inspected by an autho-
tive. rized KAESER Service Technician.
Leaks in the machine. Tighten all loose connections, repair or
replace defective parts.
Leaks in the air supply system. Check for open valves, loose connec-
tions, defective parts or gaskets, etc.
and seal or replace.
The air demand is greater than the ca- Reduce the air demand or install addi-
pacity of the compressor. tional compressor capacity.
The maintenance hose/coupling is still Remove hose/coupling from the con-
plugged into the oil separator or after- nection point.
cooler.
Pressure relief valve blowing off. see chapter 8.6.6.

8.6.4 Oil running out of air filter.

Possible cause: Remedy:

Oil level in the separator tank too high. Drain off oil till the correct level rea-
ched.
Defective inlet valve. Have the valve inspected by an autho-
rized KAESER Service Technician.

8 --- 33
 Operation

8.6.5 Too frequent switching between load and idle

Possible cause: Remedy:

No air receiver installed or receiver too Refer to a KAESER service agency for
small to function correctly as a buffer. advice on correct air receiver size.
Diameter of pipe connecting compres- The diameter of the air pipe should not
sor and air receiver too small. be less than that of the air connection.
Minimum pressure/check valve not air- Have the valve inspected by an autho-
tight. rised KAESER service agent.
Reduced flow to the air main connec- Check filter elements for clogging.
tion. Open any partially opened valves fully.
Defrost any frozen air lines.
Replace defective pressure regulator.

8.6.6 Pressure relief valve blowing off

Possible cause: Remedy:

Machine does not vent in idle running. Ensure that the venting line ball valve
is open. Have an authorized KAESER
Service Technician check the control
line, inlet valve and control venting
valve.
Oil separator cartridge clogged. Check the pressure drop and change
the cartridge if necessary.
Minimum pressure/check valve not Have the valve inspected by an autho-
open. rized KAESER Service Technician.
Pressure relief valve not suitable for Compare the valve blow ---off pressure
the compressor’s pressure range. with the information on the compres-
sor nameplate. If necessary, have an
authorized KAESER Service Technician
replace the valve.

8.6.7 Oil in the package

Possible cause: Remedy:

Maintenance hose or coupling still Remove hose/coupling from the con-
plugged into the air receiver connec- nection point.
tion point.
Pressure relief valve blowing off. see chapter 8.6.6.
Oil running out of air filter. see chapter 8.6.4.
Air receiver hose coupling loose. Tighten up hose coupling or replace
as necessary.
Oil cooler leaking. Have the oil cooler replaced by an au-
thorized KAESER Service Technician.

8.6.8 Cooling fluid consumption too high

Possible cause: Remedy:

Unsuitable cooling fluid used. Replace with recommended cooling
fluid.
Refer to authorised KAESER service
agent for advice on oil types.

8 --- 34
 Operation

Possible cause: Remedy:

Fluid separator cartridge split. Check pressure drop across the sepa-
rator cartridge and replace if neces-
sary.
Fluid separator tank cover not securely Tighten up fixing screws.
fixed.
Fluid level in the separator tank too Drain off cooling fluid until the correct
high. level is reached.
Fluid scavenge line clogged. Check dirt trap strainer in the scav-
enge line.
Clean or replace as necessary.

8 --- 35
 Maintenance

9 Maintenance

9.1 Observe the following during all maintenance and servicing.

Disregarding these notes and/or improper handling may result in seri-

ous injury.

Work on power-- driven equipment may only be carried out or super-

vised by persons trained in that particular equipment or by a special-
ist.

Work on electrical equipment in the compressor may only be carried

out according to electrical engineering regulations by a qualified elec-
trician, or trained personnel under the supervision of a qualified elec-
trician.

Before starting any maintenance work switch off at the main switch
and lock off to secure against unwanted or accidental switching on.

The complete machine must be depressurised before opening or re-

moving any pressure -- retaining components.
Check all machine hose connectors with a hand -- held pressure gauge
to ensure that all read 0 bar.

Make sure the machine is shut-- off or isolated from the air main during
maintenance work to ensure that no compressed air flows back from
the main.

Before switching on again ensure that all maintenance personnel are

clear of the machine, that all panels are replaced and all access doors
closed.

Attention! The venting nozzle required to vent the oil separator tank (for mainten-
ance work such as topping up the oil, oil change and filter change) is
fitted to the hose coupling (3, see chapter 9.10).

Carry out a visual and functional check of the door interlock switch
after any maintenance and servicing work.

See chapter 7.7 for details.

The following points must be observed when handling lubricating and

cooling materials:

Avoid contact with skin and eyes.

Do not inhale vapours 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.

9 --- 36
 Maintenance

9.2 Regular Maintenance

Interval* Work to be done See chapter

24 h after initial start Check the tension of the V---belts 9.4

50 h after initial start Check all electrical connections for tightness

200 h after initial start Change the fluid filter 9.11

Weekly Check the fluid level 9.12

Check the filter mat for clogging 9.6

500 h Check the tension of the V---belts 9.4

Clean or change the air filter 9.7

1000 h Check the fluid/air cooler for clogging 9.13

Clean or change the filter mat 9.6

up to 3000 h or at Change the fluid filter 9.11

least annually

Variable Change the cooling fluid 9.14

(see chapter 1.8)

up to 9000 h or at least Change the fluid separator cartridge 9.15

every 3 years

Annually Check all electrical connections for tightness

Check the pressure relief valve 9.9

12000 h Have the valves inspected by an authorized

KAESER Service agent

6000/12000 h or at Have the drive motor bearings changed by an 9.8

least every 3 years authorized KAESER Service agent

* The maintenance period can vary depending on the motor switching frequency and envi-
ronmental conditions.
We urgently recommend that a record is kept of all servicing done (see chapter 9.16) and
that the compressor package --- especially safety devices --- are checked annually by an
authorized KAESER service agency.

9 --- 37
 Maintenance

9.3 Opening and Closing the Compressor Package

To open:
! Open the access door (1).
! Move the lever (A) in the direction of the arrow and lift up the access door (2).
! Loosen the screws (B) and remove the panel (3).

To close:
! Close the panel (3) the access door (2) and the access door (1) in the reverse order.

Close all access doors and panels correctly before starting the com-
pressor package.

A B
3

1
B

1 Access door
2 Access door
3 Cover panel

9 --- 38
 Maintenance

9.4 Checking the Tension of the V---belts

! Switch off the compressor package (see chapter 8.3).
Switch off and lock out the main switch to prevent accidents during
maintenance.
Check the tension of the V---belts after the first 24 hours of operation and then every
500 hours of operation.

2
1

1 Hexagonal nut
2 Hexagonal nut
3 Marking pin
The V---belt tension is automatically adjusted within a limited range by the pressure spring
of the belt tensioning device.
Re---tension the V---belts if they have stretched to the point where the marking pin (3) is
located at the top end of its indicator slot.
! Loosen the hex nut (2).
! Re---tension the V---belts with the hex nut (1) until the marking pin (3) is located at the
bottom end of its slot.
! Tighten the hex nut (2).

9.5 Changing the V belts

! Switch off the compressor package (see chapter 8.3).
Switch off and lock out the main switch to prevent accidents during
maintenance.
! Loosen the hex nut of the swing frame adjustment (2, see chapter 9.4)
! Screw the hex nut (1, see chapter 9.4) until the V---belts are loose.
! Remove the V---belts.
Attention! It is essential that replacement belts are all precisely the same length
(each set) and absolutely oil -- proof. For this reason we recommend
that only original KAESER drive belts are used.
! Place the new V---belts over the motor and compressor pulleys without straining them.
! Set the V---belt tension (see chapter 9.4).
Attention! Check the V-- belt tension after two hours of operation and then again
after 24 hours of operation, as experience shows that the belts stretch
mostly during this period.

9 --- 39
 Maintenance

9.6 Cleaning or Renewing the Filter Mat

Check the filter mat weekly for clogging and clean, or renew if necessary as detailed in the
regular maintenance table (see chapter 9.2) .
! Switch off the compressor package (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

1 3

2
3

3
1 Filter
2 Mounting frame
3 Closure

! Press closures (3) inwards and remove the mounting frame.

Cleaning:
Rinse the mat in water of approximately 40!C, if necessary, use a mild washing powder.
The mat can also be tapped, vacuum cleaned or blown out with compressed air. Rinse out
oily dust using warm water with a mild solvent additive.

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

! Locate the mounting frame and press into position.

The mounting frame is secure when the closures engage.

9.7 Cleaning or Renewing the Air Filter

Clean the air filter after every 500 service hours.
! Stop the compressor unit (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

9 --- 40
 Maintenance

1 3

1 Air filter
2 Air filter cap
3 Wing nut for opening air filter housing
4 Air filter cartridge
To open the air filter housing:
! Unscrew the wing nut (3) and remove the air filter cap (2) and the filter cartridge (4).
! Clean the air filter cap 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 force otherwise the air filter cartridge may be damaged.
! Clean all sealing surfaces.
Cleaning the air filter cartridge with compressed air:
! Blow dry compressed air at a pressure of not more than 5 bar at a slant from the in-
side 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), renew.
To close the filter housing:
! Insert the filter cartridge (4) and replace the air filter cap (2).
! Screw on the wing nut (3) tightly.

9.8 Servicing the Electric Motor

Compressor motor:
The electrical motor bearings are permanently greased.
Attention! Have the motor bearings replaced using the KAESER Service in ac-
cordance with the maintenance schedule (see chapter 1.11).

9.9 Checking the Pressure Relief Valve on the Oil Separator Tank
To check the operating pressure of the pressure relief valve the final pressure of the
compressor package must be increased above the pressure parameter entered in the
controller.
See chapter 1.5 for the operating pressure of the pressure relief valve.
Attention! The pressure relief valve must be checked by an authorized KAESER
service agency when the interval quoted in the regular maintenance
table (see chapter 9.2) has expired.

Detailed information is to be found in the service manual for SIGMA

CONTROL.

9 --- 41
 Maintenance

9.10 Venting the Compressor Package

! Shut down the compressor package (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

! Close the shut ---off valve between the compressor package and the air main.
The oil circulation vents automatically.
Venting the oil separator tank:
11

3
A
2

B 4
5

9
10
8

1 Shut --- off valve 4 Filler plug 8 Maximum oil level

A shut (oil top --- up) 9 Shut ---off valve --- oil drain
B open 5 Oil separator tank 10 Oil drain hose
2 Pressure gauge 6 Plug --- in nipple 11 External pressurization
3 Hose coupling 7 Minimum oil level

! The pressure gauge on the oil separator tank must indicate zero bar.

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

! Insert the nipple (6) in the hose coupling (3) on the oil separator tank (the residual
pressure in the oil separator tank escapes).
! Remove the nipple (6) from the hose coupling (3).

9 --- 42
 Maintenance

Venting the air-- cooler:

When the compressor package is vented, the air-- cooler and the pipe-
work up to the minimum pressure check valve are still under pressure.
For this reason the compressor package must be isolated from the air
main (close the user’s shut-- off valve). If a shut-- off valve is not avail-
able, vent the air main completely.

! Carefully remove the pipe fitting (4, see chapter 9.13). The air---cooler vents.
! Tighten the pipe fitting again.

Close all access doors and panels correctly before starting the com-
pressor package.

9.11 Oil Filter Change

Hot oil; beware of scalding.

During the running in period, a running ---in oil filter cartridge is fitted to clean the oil sys-
tem.

Attention! Replace the running -- in oil filter cartridge with a standard oil filter car-
tridge after approximately 200 operating hours.

A further filter change is recommended after the interval quoted in the regular maintenance
table (see chapter 9.2) or when the corresponding service message is displayed on SIGMA
CONTROL (see chapter 8.1). The filter must be changed after every oil change.

9.11.1 Removal and replacement of the oil filter

! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

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 9.10).

1 Oil filter cartridge

2 Turn in this direction to unscrew the cartridge

9 --- 43
 Maintenance

! Spin off the used or contaminated oil filter counter---clockwise and catch escaping oil
in a suitable container.

Dispose of the used filter and used oil carefully according to environ-
mental regulations.

! Clean the sealing faces carefully with lint free cloth.

! Lightly oil the gasket of the new oil filter before screwing into position.
! Spin on the new oil filter clockwise by hand until the gasket fits tightly.

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

! Check the oil level (see chapter 9.12).

! Open the shut ---off valve between the compressor package and the air main.

Carry out a trial run.

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

down the compressor package (see chapter 8.3) and lock out the main
switch to prevent an accidental compressor run.

Carry out a visual check for leaks.

9.12 Topping up the Oil

Check the oil level weekly at the oil level sight glass with the compressor shut down. If
necessary, top up the oil to the maximum level. To do this shut down the compressor in the
full load phase and wait five minutes for the oil level to settle. Do not exceed the maximum
level (centre of the oil level gauge).
! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

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 9.10).

9 --- 44
 Maintenance

11

3
A
2

B 4
5

9
10
8

1 Shut --- off valve 4 Filler plug 8 Maximum oil level

A shut (oil top --- up) 9 Shut ---off valve --- oil drain
B open 5 Oil separator tank 10 Oil drain hose
2 Pressure gauge 6 Plug --- in nipple 11 External pressurization
3 Hose coupling 7 Minimum oil level

! Unscrew the oil filler plug (4) on the oil separator tank.
! Top up the oil to the maximum mark.
! Check the sealing ring of the filler plug (4) for damage and then replace the filler
plug (4).
! Open the shut ---off valve between the compressor package and the air main.

Attention! After carrying out the oil change or oil cooler cleaning (with removal of
the oil cooler) run the compressor package up to operating tempera-
ture 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 9.10) and “Topping up the Oil” (chapter 9.12).

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

If the type of oil is changed, drain the old oil completely and renew the
oil filter.

Never use different types of oil.

9 --- 45
 Maintenance

9.13 Cleaning the Oil Cooler and Air Cooler

The oil cooler and air cooler must be checked for clogging regularly. Heavy clogging may
cause high temperatures in the oil circulation.
See regular maintenance table for cooler service interval (chapter 9.2).
! Switch off the compressor unit under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor start.

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 9.10).

9.13.1 Removing and cleaning the oil/air cooler

2
4

1 Allen screw
2 Hose screw fitting
3 Pipe screw fitting
4 Pipe screw fitting

! Unscrew the hose connector (2) and the pipe connector (3) from the combination
valve.
! Unscrew the hex socket head screws (1) on the air cooler.
! Remove and check the O---ring on the air cooler.
! Close up the pipes and openings on the combination valve and air cooler.

9 --- 46
 Maintenance

5 Hexagonal nut
6 Allen screw

! Unscrew the hex bolt (5).

The hex socket head bolts (6) are located behind two protective caps.

Attention! Before unscrewing the two hex socket head bolts (6) prop up the air/
oil cooler.

! Remove the protective caps and unscrew the two hex socket head bolts (6).
! Take out the air/oil cooler.

Do not direct compressed air, water or steam jets at persons. These

jets represent contained energy and as such are dangerous to life!

Clean the soiled cooler with water or steam jet in washing areas that
that are suitable for such cleaning work and provided with an oil sep-
arator!

! Clean the cooler cells with compressed air, water or steam jet.
! Reassemble in the reverse order.

Attention! Seat the O rings correctly in the compressed air inlet of the air cooler
during reassembly.

! See chapter 9.12 for topping up the oil.

! Open the shut ---off valve between the compressor package and the air main.

Carry out a trial run.

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

down the compressor package (see chapter 8.3) and lock out the main
switch to prevent an accidental compressor run.

Carry out a visual check for leaks.

9 --- 47
 Maintenance

9.14 Oil Change (Oil Separator and Oil Cooler)

Carry out the oil change with the compressor at operating temperature.

Hot oil; beware of scalding!

The oil change interval is dependent on the degree of cooling air contamination and on the
ambient temperature.
If the compressor package is operated close to the maximum permissible ambient tem-
perature (see chapter 1.6), the oil must be changed more often, if necessary, the interval
should be halved.

Attention! Drain the oil out of the separator tank, cooler and the pipework com-
pletely. See chapter 9.14.4 for putting back into operation.

! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

11

3
A
2

B 4
5

9
10
8

1 Shut --- off valve 4 Filler plug 8 Maximum oil level

A shut (oil top --- up) 9 Shut ---off valve --- oil drain
B open 5 Oil separator tank 10 Oil drain hose
2 Pressure gauge 6 Plug --- in nipple 11 External pressurization
3 Hose coupling 7 Minimum oil level

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 9.10).

9 --- 48
 Maintenance

9.14.1 Draining the oil using external pressure source

! Close the shut ---off valve (1).
! Insert the nipple (6) in the hose coupling (3) on the oil separator tank (5).
! Apply external pressure source to the nipple until the pressure gauge (2) on the oil
separator tank (5) indicates approximately 3 bar.
! Remove the nipple (6) from the hose coupling (3) on the oil separator tank (5).
Draining the oil at the oil separator tank:
! Prepare a container to catch escaping oil.
Attention! The container must be large enough to hold the total oil content of the
compressor package (see chapter 1.7).
! Hang the oil drain hose (10) in the canister and secure.
! Slowly open the shut ---off valve (9) (the remaining pressure in the oil circuit forces out
the oil). Close the shut ---off valve (9) immediately when air escapes.
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 9.10).

1
1 Oil drain plug (oil cooler)
Drain the oil from the oil cooler:
! Prepare an oil container to catch the oil.
! Slowly unscrew the oil drain plug (1). The oil drains out under the force of gravity.
! Screw the oil drain plug (1) back in tightly.
Dispose of the old oil according to environmental regulations.

9.14.2 Adding oil

! Unscrew the oil filler plug (4) on the oil separator tank.
Attention! Always use the same brand and type of oil when topping up the oil.
(see label on the oil separator tank).

If a different type of oil is used drain the old oil completely and always
renew the oil filter.

Never mix different types of oil.

! Top up the oil to the maximum mark.
For oil quantity see chapter 1.7.
! Check the sealing ring on the oil filler plug (4) for damage and then screw in the oil
filler plug.

9 --- 49
 Maintenance

9.14.3 Draining the oil using own compressed air

! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

! Close the shut ---off valve between the compressor package and the air main.
The compressor oil circulation vents automatically.
! The pressure gauge on the oil separator tank must indicate zero bar.
! Close the shut ---off valve (1).

Close all access doors and panels correctly before starting the com-
pressor package.

! Start the compressor package (see chapter 8.3) and allow to run for approximately 30
seconds.
! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

! 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 3 bar 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 9.14.1.
! Open the shut ---off valve (1).
! Top up with oil as described in chapter 9.14.2.

9.14.4 Measures for putting back into operation

! Carry out measures detailed in ‘‘Pouring a small quantity of oil into the air inlet port”
see chapter 7.8.1.
! Carry out measures detailed in ‘‘Running the compressor package in idle”
see chapter 7.8.2.
! Carry out the measures detailed in ‘‘Venting the compressor package”
see chapter 9.10.
! Top up with oil, see chapter 9.14.2.
! Open the shut ---off valve between the compressor package and the air main.
! Switch on the compressor package, see chapter 8.3, and allow to run until the operat-
ing temperature is reached, see chapter 1.1.
! Top up the oil again, see chapter 9.12.

Carry out a trial run.

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

down the compressor package (see chapter 8.3) and lock out the main
switch to prevent an accidental compressor run.

Carry out a visual check for leaks.

9 --- 50
 Maintenance

9.15 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 is displayed on SIGMA CONTROL (see chapter 8.1).
! Shut down the compressor package under full load (see chapter 8.3).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

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 9.10).

6
7
4
2 8
3

7
5 6
9

10
11
12

2 Hose coupling 5 Cover 9 O ---Ring

3 Pressure gauge 6 Gasket 10 Gasket
4 Hexagonal nut 7 Metal clip 11 Dirt trap screen filter
8 Oil separating cartridge 12 Screw fitting with jet

The metal parts of the oil separator cartridge are electrically conduc-
tive and thus require ”electrically conductive gaskets”. The gaskets (6)
are fitted with metal clips (7) that fulfil this requirement and provide an
electrical path to the oil separator tank and to the frame of the com-
pressor package.

Do not remove the metal clips.

! Unscrew the hexagonal bolts (4) and remove cover plate (5).
! Take out the old oil separator cartridge (8) together with the gaskets (6) and O ring (9).
Dispose of the old parts according to environmental regulations.
! Clean the sealing surfaces of the oil separator tank.

9 --- 51
 Maintenance

Attention! The oil separator cartridge is disposable and cannot be cleaned.

! Insert the new O ring (9) in the groove in the oil separator tank.
! Insert the new oil separator cartridge (8) with new gaskets (6), fit and tighten down the
cover plate (5) with the hexagonal bolts (4).
! Renew the strainer (11) and the gasket (10) when the oil separator cartridge (8) is re-
newed.
! Open the shut ---off valve between the compressor package and the air main.

Carry out a trial run.

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

down the compressor package (see chapter 8.3) and lock out the main
switch to prevent an accidental compressor run.

Carry out a visual check for leaks.

9 --- 52
 Maintenance

9.16 Record of Maintenance Work

Serial number of the unit:

Date Description of work Service hours Signature

9 --- 53
 Spare Parts and After Sales Service

10 Spare Parts and After Sales Service

10.1 Service parts and expendable parts

The removal of faults that are not explicitly described in this service
manual may only be carried out by KAESER or by an authorised
KAESER service agent.

KAESER KOMPRESSOREN GmbH

Carl--- Kaeser--- Str. 26, 96450 Coburg
GERMANY Telefon + 49 95 61 64 00
Fax + 49 95 61 01 30

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Year of production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kW

Rated motor speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm

Max. working pressure(g) . . . . . . . . . . . . . . . . . . . . . . . . . . bar

Ambient temperature . . . . . . . . . . . . . . . . . . C / . . . . . . . . C

Important for all queries:

! Enter the data on your compressor’s nameplate in the nameplate shown above.
Always quote the data on the nameplate when making a query or ordering spares.

Attention! Always order original spares from the compressor manufacturer to

avoid lowering the quality of your compressor package.

Supplementary information for specialised personnel concerning spare parts is found in

chapter 11.2.

Description No. off Order No.

Oil filter 1 1200

Air filter cartridge 1 1250

Filter mat 1 1050

Oil separator cartridge

Complete set 1 1450

Comprising:
Separating cartridge 1
Gasket 2
O Ring 1
Dirt screen filter 1
Gasket 1

V---belt set 1 1800

10 --- 54
 Spare Parts and After Sales Service

10.2 Service and Maintenance Agreement

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

10 --- 55
 Appendix

11 Appendix

11.1 Electrical Diagram

11 --- 56
 Appendix

11.2 Spare Parts List

11 --- 73
SERVICE MANUAL USE

Refrigerated Dryer
Model: TU 26
GL---Nr.: BA---TU26---1.8014.20110
Index: 000801

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

 Table of Contents
Chapter --- Page

1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Refrigerated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.3 General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.4 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4
2.5 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6
3.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6
3.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7
4.2 Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 8

5.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 8
5.2 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 8
5.3 Refrigerant Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 8
5.4 ECO---DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 9
5.4.1 Condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 9
5.4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 9
5.4.3 Operational Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 9
5.4.4 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 10
5.5 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11
5.6 Pipe and Instrument Flow Chart (P & I Flow Chart) . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 11

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 14
6.1 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 14
6.2 Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 15
6.3 Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16
6.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 16

i
 Table of Contents
Chapter --- Page

7 Preparation For Initial Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 17

7.1 Points to be Observed before Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 17
7.2 Points to be Observed before Starting the Refrigerated Dryer . . . . . . . . . . . . . . 7 --- 17
7.3 Ready for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 18

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 19
8.1 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 19
8.2 Starting the Refrigerated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 20
8.3 Stopping the Refrigerated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 21
8.4 To be Observed when Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 21
8.5 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22
8.5.1 Water in the compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22
8.5.2 High pressure losses via the refrigerated dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22
8.5.3 Pressure dew point too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 22
8.5.4 High compressed air losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 23
8.5.5 Red LED on the ECO---DRAIN housing flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 23
8.5.6 The safety pressure switch shuts down the refrigerated dryer . . . . . . . . . . . . . . 8 --- 23

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 24
9.1 Maintenance Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 24
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 24
9.2.1 Check the condensate outlet daily as follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 24
9.2.2 Check ECO---DRAIN for proper operation monthly, as follows: . . . . . . . . . . . . . . 9 --- 25
9.2.3 Cleaning the condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 25
9.2.4 General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 25
9.2.5 Cleaning the ECO---DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 26

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 29

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 30
11.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 30
11.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 38

ii
 Technical Specification

1 Technical Specification

1.1 Refrigerated Dryer

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TU 26
Condensate volume under nominal conditions* . . . . . . . . 28,5 oz/h
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 lbs
Cooling air volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 cfm
Noise level to CAGI---Pneurop . . . . . . . . . . . . . . . . . . . . . . . . < 70 dB(A)
at 1 m distance (free sound field measurement)
* See chapter 1.2 for nominal conditions.

Drawings:
P & I flow chart . . . . . . . . . . . . . . . . . . . . FKTTU26ST---00027.01
(Pipework and instrument flow chart)
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . STU---U0908.00

1.2 Compressed Air System

Flow volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 scfm
Pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,62 psid
Pressure dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 !F
at 100 !F air inlet, 100 psig and 100 !F ambient temperature.
Maximum gauge working pressure . . . . . . . . . . . . . . . . . . . . 230 psig

1.3 Refrigerant System

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R 134a
Maximum quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,54 lbs
Permissible gauge working pressure . . . . . . . . . . . . . . . . . . . 260 psig

1.4 Installation Requirements

Max. elevation above sea level of installation . . . . . . . . . . . 3000 ft.
(for all elevations above please contact authorized KAESER distributor)
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 !F
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 !F
Maximum compressed air inlet temperature . . . . . . . . . . . . . 130 !F

1.5 Connections
Compressed air outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NPT
Condensate drain connection (hose connection) . . . . . . . 3/8”
Service connection (Schrader valve) . . . . . . . . . . . . . . 7/16 UNF

1 --- 1
 Technical Specification

1.6 Electrical Connection

Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 V ± 10 % 1---phase
Full load current, FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A
Recommended power supply cable (Cu multi---stranded )
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 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.

1.7 Settings
Safety pressure switch (refrigerant)
switching point (fixed)
POFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 psi

1.8 Designation
The nameplate of the dryer is located on the back, next to the compressed air connection
(see chapter 10 for the illustration of the name plate).

1 --- 2
 Safety

2 Safety Regulations

Read this service manual very carefully and observe all cautionary references before the
initial start of this refrigerated dryer and before carrying out any maintenance on the unit.

2.1 Explanation of Symbols and References

This symbol is placed before all safety references where there is dan-
ger to life and limb. It is especially important that any associated in-
structions are followed explicitly and that extreme care is taken when
performing the indicated task(s). For their own protection, inform all
other users of these safety rules. Observe general safety and accident
prevention regulations as well as the safety rules laid down in this ser-
vice manual.

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

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

This symbol identifies environmental care measures.

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

service technician.

" This bullet identifies listings.

2.2 General Safety Instructions

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

Work on the electrical equipment of the refrigerated dryer may only be

carried out by a qualified electrician or trained personnel under the
supervision of a qualified electrician according to the NEC and any ap-
plicable local codes.

Work on the refrigeration system may only be carried out by a certified

refrigeration technician (according to 40CFR Part 82).

2 --- 3
 Safety

2.3 General References

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

instructed personnel or by specialized personnel.

Work on the electrical equipment of the refrigerated dryer may only be

carried out by a qualified electrician or trained personnel under the
supervision of a qualified electrician according to the NEC and any ap-
plicable local codes.

Work on the refrigeration system may only be carried out by a certified

refrigeration technician (according to 40CFR Part 82).

The refrigerated dryer contains activated electrical components.

Carry out the following measures in the sequence shown before
attempting any work on the electrical system:

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 refrigerated dryer does not restart.

2. Ensure the unit 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 in the refrigerated dryer or in the piping
between the dryer and the isolation shut-- off valve in accordance with
applicable lock out/ tag out procedures (example: OSHA CFR 29
§ 1910.147).

The refrigerated dryer contains systems subject to high pressures.

Before any maintenance work is carried out, vent and shut off the pres-
sure lines.

Escaping compressed air and/or refrigerant can cause injury to per-

sonnel and lead to damage to the dryer.

The refrigerant contained in the refrigerating system may not be

vented to the open air. Always use a refrigerant recovery system when
working on the refrigerant circulation.
Dispose of unusable refrigerant according to environmental regula-
tions!

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

2.4 Spare Parts

The use of KAESER original parts guarantees safe and reliable operation of the refrigerated
dryer.

2 --- 4
 Safety

2.5 Environmental Protection

Condensate drainage

The condensate accumulated during the drying of compressed air

must be removed via a suitable drainage system, collected in special
canisters and disposed of according to federal and local environmen-
tal regulations.

Maintenance materials/wear items/replacement parts

Ensure that all wear items, maintenance and replacement parts accu-
mulated during operation of the refrigerated dryer are disposed of ac-
cording to environmental regulations.

2 --- 5
 General

3 General

The service manual must always be available for use at the location of
the refrigerated dryer.

3.1 Proper use

The refrigerated dryer is intended solely for drying compressed air.
Any other use outside of this purpose is considered improper. The manufacturer cannot
accept liability for any damage caused by improper use; the user alone is liable for any
risks incurred.
Proper use of the dryer includes compliance with the installation, removal, servicing, opera-
tion and maintenance instructions as specified by the manufacturer.

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

3 --- 6
 Transport

4 Transport

4.1 Transport Instructions

Attention! Under no circumstances lift the refrigerated dryer with the compressed
air inlet and outlet connections or lay the refrigerated dryer on its side.
Serious damage can result from such treatment of the refrigerated
dryer.
To prevent damage to the panelling of the refrigerated dryer always
use a jack lift or a forklift truck for transport.

! Always mount the refrigerated dryer on a suitable transporting medium (pallet or woo-
den base) during transport.

min. 32”

min. 40”

Attention! Do not exert any side forces on the refrigerated dryer with lifting equip-
ment.

4.2 Temporary Storage

Store the refrigerated dryer in an enclosed space, regardless of whether it is packaged or
not.
The storage temperature should not fall below ---13!F and not rise above 140!F.

Attention! Before initial start, wait until the temperature of the refrigerated dryer
has adapted to the ambient temperature.

4 --- 7
 Construction and Operation

5 Construction and Operation

Items referred to in ( ) correspond with the items in the Pipe and Instrument Flow Diagram
(see chapter LEERER MERKER).

5.1 Construction
The main component of the refrigerated dryer comprises a combined heat exchanger (heat
transmitter). It consists of the two following main groups:
1st. stage: air to air heat exchanger (1)
2nd. stage: air to refrigerant heat exchanger (2)
A condensate separating system (3) is fitted in series with the heat exchanger.
A safety pressure switch (9) is fitted in the refrigerant circulation system as a protection
against excessive pressure.
A thermal overload switch protects the refrigerant compressor (11) against current over-
loads and high temperatures.

The refrigerated dryer housing is designed for mounting beneath a compressor of the
same manufacturer.

5.2 Functional Description

The dried compressed air is then rewarmed by flowing through the air to air heat ex-
changer (1) before leaving the refrigerated dryer.
The warm compressed air of high humidity entering the unit is initially cooled in the air to
air heat exchanger (1) through heat exchange with the cooled compressed air leaving the
unit.
Further cooling occurs in the air to refrigerant heat exchanger (2), connected in series with
the air to air heat exchanger through the action of expanding, gassing refrigerant. This ac-
tion causes the humid components of the compressed air to condense out when the pres-
sure dewpoint is undercut.
The condensate separator, (3) connected in series, separates the condensed water and oil
droplets, together with coarse dirt particles, from the compressed air. This condensate is
removed from the system by an automatic condensate drain (5).
The cooling action of the refrigerated dryer causes the condensation and subsequent sep-
aration of the humid content of the compressed air.
The hot gas bypass valve (19) automatically regulates the refrigeration capacity needed in
part load operation.

5.3 Refrigerant Circulation

The dryer is able to cool the compressed air by using a refrigeration system not unlike a
typical home refrigerator. Cooling is achieved by transferring heat from the compressed air
to the refrigerant by vaporizing (boiling) the refrigerant, thereby turning the refrigerant into
a gas. A more complete description of this process is given below:
The refrigerant enters the hermetically sealed compressor (11) as a low pressure gas. The
gas is compressed to a suitable pressure to ensure that the gas is nearly saturated. The
high pressure refrigerant gas flows to the condenser (10) where heat is removed from the
refrigerant. As the high pressure refrigerant gas is cooled, the refrigerant becomes a liquid.
The high pressure liquid is then forced through a capillary tube (7). By forcing the refriger-
ant through this restriction, the refrigerant becomes a low pressure liquid. The low pres-

5 --- 8
 Construction and Operation

sure, liquid refrigerant enters the evaporator (2) where heat from the compressed air is
transferred to the refrigerant. The added heat causes the refrigerant to boil and results in
the refrigerant becoming a low pressure gas. This becomes an endless cycle which allows
the refrigerant to simply remove heat from the compressed air and expel it to the ambient
air.

5.4 ECO ---DRAIN

5.4.1 Condensate drainage

Once the moisture has been condensed and collected, the liquid must be drained from the
dryer. The ECO---DRAIN provides a reliable means to remove the liquid without wasting
compressed air.

5.4.2 Function
Any moisture that is condensed flows to a low point where it enters the drain trap at the
inlet opening (1). The moisture is collected in the drain trap chamber (2). Once the cham-
ber is full, the electronic sensor (3) energizes the electronic controller (7). The controller
opens a small pilot port which allows the diaphragm valve (4) to open. As the liquid level
drops, the electronic sensor closes the valve again before any compressed air can escape.
8

1 2 3 4 5
1 Inlet opening 5 Outlet line
2 Collector 6 Housing
3 Level detector 7 Electronic control
4 Diaphragm valve 8 Light ---emitting diode

! If a fault occurs (e.g. overload), the valve cycles on and off continuously to clear the
fault. The light ---emitting diode flashes.

5.4.3 Operational Status Indicator

The operational status of the condensate drain is indicated by a red LED (8) on the hous-
ing of the ECO---DRAIN. The LED will indicate one of the following conditions:
1 LED on permanently:
the drain is operational
2 LED extinguishes for a short period:
the drain is discharging moisture
3 LED flashing continuously:
a fault exists

5 --- 9
 Construction and Operation

5.4.4 Functional check

Check the function of the ECO---DRAIN by pressing the TEST pushbutton (9). The ECO---
DRAIN will switch to the discharge mode every 2 to 3 seconds as long as the button is de-
pressed. The LED (8) flashes at the same interval.

8 9
8 Operational status --- light emitting diode
9 TEST pushbutton (condensate drain)

5 --- 10
 Construction and Operation

5.5 Component Identification

Numbers in ( ) correspond to those in the Pipe and Instrument Flow Chart.
(P & I Flow Chart).

1 2 3 4 5

14

13

13 8 11 10 14 2 12
1 Operating panel 8 Capillary tube (7)
2 Control cabinet 9 Hot gas bypass valve (19)
3 Condensate ECO ---DRAIN (5) 10 Safety pressure switch (9)
with outlet hose 11 Fan pressure switch
4 Shut ---off valve (4) 12 Condenser (10)
5 Refrigerant compressor (11) 13 Filter dryer (8)
6 Compressed air inlet 14 Heat exchanger with integrated
7 Compressed air outlet moisture separator (1), (2), (3)

5.6 Pipe and Instrument Flow Chart (P & I Flow Chart)

(see following pages)

5 --- 11
Construction and Operation

5 --- 12
Construction and Operation

5 --- 13
 Installation

6 Installation

6.1 Installation Requirements

The refrigerated dryer must be installed in a dry and dust free space. To ensure adequate
room for the maintenance of the refrigerated dryer, the minimum distances must be com-
plied with (see following sketch).
Install the dryer on an even flat surface. Special foundations for the installation of the refrig-
erated dryer are not necessary.
See chapter 1.4 for the the ambient temperature and maximum height of the place of
installation.

Attention! To ensure adequate ventilation and air circulation, be sure to allow for
the indicated minimum clearances at the cooling air inlet and exhaust.

The refrigerated dryer must not be installed in the air inlet and/or coo-
ling air outlet area of a compressor package.
The compressed air to be dried and the ambient air in the compressor
space may not contain any acid -- forming or other aggressive materi-
als.

Attention! The refrigeration dryer may only be installed beneath a compressor of

the same manufacturer.

Consult the compressor technical specification and installation in-

structions.

6 --- 14
 Installation

Exhaust ventilator

min. 87
Exhaust Air inlet
duct opening

28

20

min. 87

32
min. 87
Measurements in inches

Attention! Installing of inlet and/or exhaust air ducting without prior written ap-
proval from of KAESER COMPRESSORS Inc. is not permitted.

6.2 Compressed Air Connection

Attention! Use flexible connecting pipes at the compressed air inlet and dis-
charge to ensure vibration isolation, prevent strain on piping connec-
tions and allow easy installation.
To avoid damage, do not overtighten the compressed air connections.

The refrigeration dryer is piped ready for operation.

Shut-- off valves:

All power driven systems must be equipped with a main stop system
for all forms of energy feed, the operation of which determines the
start and stop of the energy supply to the system.

The compressed air inlet and outlet pipework must be provided with shut off arrangements
(e.g. ball valves).

6 --- 15
 Installation

6.3 Condensate Drain Connection

A hose connection is provided for drainage of the condensate. See chapter 1.5 for the di-
mensions.

Attention! Use caution when attaching the condensation drain line to ensure that
the condensate flow is not obstructed.

The condensate must be drained and collected in a suitable container.

It must be disposed of in accordance with federal and local environ-
mental codes.

6.4 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 1.6.

The refrigerated dryer is delivered completely wired, ready for connection to the power
supply.This connection must be made as detailed in the electrical diagram (see
chapter 11.1). See the Airtower dimensional diagram for the position and size of the cable
entry into the refrigerated dryer.

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:

1.25 x FLA wire correction factor

(see chapter 1.6) temperature rating for 40!C
! 100A 60!C 0.82
" 100A 75!C 0.88

6 --- 16
 Preparation For Initial Start Up

7 Preparation For Initial Start Up

7.1 Points to be Observed before Start Up

Every refrigerated dryer is tested in the factory and carefully checked before shipment. The
test run confirms that the refrigerated dryer conforms to the manufacturer’s specifications
and operates as designed. However, independent of the checks made at the factory, the
refrigerated dryer could be damaged during transport. For this reason, we recommend that
the refrigerated dryer be examined for any damage. Inspect the refrigerated dryer carefully
during the first hours of operation for any possible malfunction.

Attention! The internal components of the refrigerated dryer are factory adjusted
for correct operation. Adjustments may not be made to these compo-
nents without prior written consultation with KAESER Compressors
Inc.

7.2 Points to be Observed before Starting the Refrigerated Dryer

FAILURE TO HEED THIS OR OTHER REFERENCES (WARNING;
ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO PER-
SONS OR DAMAGE TO EQUIPMENT.

Do not operate the refrigerated dryer with the side panels removed.
Operation without the panels may result in injury.

! Remove all packaging materials, tools and transport securing devices on and in the
refrigerated dryer.
" It is expected that the operator uses safe working methods when operating the refrig-
erated dryer and that all valid operating and safety provisions are followed.
" The operator of this refrigerated dryer is responsible for its safe operating condition.
" The compressed air to be dried and the ambient air of the place of installation may not
contain any acid ---forming or other aggressive materials.
" Do not connect the refrigerated dryer to a supply voltage different to that shown on the
nameplate.
" Install the refrigerated dryer in a space that is not subject to freezing conditions. See
chapter 1.4 for the minimum ambient temperature..
" Allow the refrigerated dryer to reach the ambient temperature before putting into
operation.

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 refrigerated dryer 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 opera-
tion).

7 --- 17
 Preparation For Initial Start Up

7.3 Ready for Operation

Attention! Do not start the refrigerated dryer until completing the following:

" The refrigerated dryer is installed according to the conditions stated in chapter 6.
" All electrical connections, air piping and condensate lines are correctly connected and
properly tightened.
" The shut ---off valves in the compressed air inlet and outlet lines are closed.
" The condensate drainage line is free of obstructions.
" The refrigerated dryer is supplied with the correct voltage supply.

Attention! Start the refrigerated dryer for approximately 15 minutes before open-
ing the shut-- off valves in the compressed air inlet and outlet lines.

7 --- 18
 Operation

8 Operation

During operation of the refrigerated dryer, condensate is separated from the compressed
air.

The condensate must be drained and collected in a suitable container.

It must be disposed of according to Federal and local environmental
codes.

! Collect the accumulated condensate in a container and dispose of properly.

8.1 Instrument Panel

3 2 1
1 Control switch
2 Control Voltage ON indication
3 Pressure dewpoint gauge

8 --- 19
 Operation

Explanation of the colored segment scale of the pressure dew point indication:
(suction pressure gauge)

B C

D
A

" A
Blue -- white range (low suction pressure) results in too low a pressure dewpoint due
to:
--- Evaporator temperature too low (evaporator freeze---up)
--- Dryer too large or very low air demand. Refer to chapter 1.4
" B
Green range (normal suction pressure) results in a normal pressure dew point.
" C
Green-- red range (elevated suction pressure) results in increased pressure dew point
to:
--- High ambient temperature
" D
Red range (high suction pressure) results in too high a pressure dew point due to:
--- Fault, see chapter 8.5.3 for help

8.2 Starting the Refrigerated Dryer

Attention! Switch on the refrigerated dryer only if the conditions in chapter 7.3
‘‘Ready for Operation’’ are fulfilled.

! Check the refrigerated dryer according to chapter 7.3.

! Remove the padlock provided for protection against ‘‘inadvertent switch ---on” of
switch (1).
! Rotate the switch (1) to ‘‘I’’ (ON).
The refrigerated dryer is now in operation, the control lamp (2) illuminates indicating control
voltage on.

Attention! Open the shut-- off devices in the air lines slowly after approximately
15 minutes.

8 --- 20
 Operation

! Open the shut ---off valve of the compressed air inlet slowly
(admission of the compressed air).
! Open the shut ---off valve of the compressed air outlet slowly.
The compressed air system is now connected to the refrigerated dryer.
Attention! Press RESET if the safety pressure switch has shut down the refriger-
ated dryer.

1 RESET

8.3 Stopping the Refrigerated Dryer

! Close the compressed air shut ---off valves (inlet and outlet).
Attention! The main switch (1) can be secured in the ” 0 ” position against inad-
vertent switch-- on by a small padlock.
! Turn switch (1) to ” 0 ” (OFF).
The refrigerated dryer is switched off and the control lamp is off.

8.4 To be Observed when Restarting

Attention! After switching (1) to ‘0’ (OFF), wait three minutes before switching
back to ‘I’ (ON) again. If (1) is switched back to ‘I’ (ON) within three
minutes the overload contactor will operate and automatically shut
down the dryer. If this is repeated the refrigerant compressor could be
damaged.
! If the dryer is automatically shut down in this way, wait at least 15 minutes before
switching (1) back to ‘Ì’ (ON) again.

8 --- 21
 Operation

8.5 Trouble shooting

The local safety regulations (see chapter 2) and the regulations
detailed in the ”Safety” chapter must be complied with during trouble-
shooting.
See chapter 7.3 and chapter 8.2. when starting the refrigerated dryer after the malfunction
has been corrected.

8.5.1 Water in the compressed air system

Possible cause: Fault removal:

Condensate deposits in the com- Blow out the compressed air pipe
pressed air pipe work that were work with dry air until no more mois-
formed before the dryer was put into ture condenses.
service.

Compressed air inlet and outlet swap- Check the compressed air connec-
ped tions using the dimensional diagram.
The condensate is not drained out of Check the ECO---DRAIN (see chapter
the system. 9.2.2); refer to authorized KAESER dis-
tributor.

8.5.2 High pressure losses via the refrigerated dryer

Possible cause: Remedy:

Refrigerated dryer iced up on the air Switch off the dryer until the air system
side. has thawed. If the system ices up
again after starting again, refer to
authorized KAESER distributor.

8.5.3 Pressure dew point too high

Possible fault: Remedy:

Ambient temperature too high. Check the technical data, see

chapter 1.2.

Compressed air inlet temperature is Check the technical data, see

too high. chapter 1.2.
Flow volume too high. Check the technical data, see
chapter 1.2.
Low refrigerant. Refer to
authorized KAESER distributor.
Defective refrigerant compressor. Refer to
authorized KAESER distributor.
Defective condenser fan motor. Refer to
authorized KAESER distributor.
High contamination component in the Clean the compressed air system.
compressed air causing scale in the
compressed air system.
Condenser surface (refrigerant lique- See maintenance instructions
fier) contaminated. chapter 9.2.3.

8 --- 22
 Operation

8.5.4 High compressed air losses

Possible fault: Remedy:

Constant loss of pressure via the con- Clean the ECO---DRAIN (see chap-
densate drain. ter 9.2.5).

8.5.5 Red LED on the ECO -- DRAIN housing flashes

Possible cause: Remedy:

Condensate not draining. Check the ECO---DRAIN (see

chapter 9.2.2); contact authorized
KAESER distributor.

8.5.6 The safety pressure switch shuts down the refrigerated dryer

Possible fault: Remedy:

Ambient temperature too high. Check the technical data, see

chapter 1.2.

Condenser surface (refrigerant lique- See maintenance instructions

fier) contaminated. chapter 9.2.3.

Defective condenser fan motor. Refer to authorized KAESER distrib-

utor.

8 --- 23
 Maintenance

9 Maintenance

9.1 Maintenance Instructions:

Before starting work, follow the procedure below to ensure the unit is
not started or energized while maintenance work is being performed:

Work on the electrical equipment of the refrigerated dryer may only be

carried out by a qualified electrician or trained personnel under the
supervision of a qualified electrician according to local codes.

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 dryer does not restart.

Before starting work, carry out the following procedure to prevent inadvertent ap-
plication of power to the refrigerated dryer:
! turn switch (1) to ‘‘ 0 ’’.
! lock out the switch (1) using a suitable padlock.
Before restarting the refrigerated dryer, ensure that:
" no maintenance personnel are working on the refrigerated dryer.
" all tools are removed from the refrigerated dryer.
" all guard and cover panels are properly installed and secured.
See chapter 7.3 and 8.2 for starting the refrigeration.

9.2 Regular Maintenance

Period Work to be done see chapter

Daily Check the condensate outlet 9.2.1

50 hours after initial Clean the ECO---DRAIN 9.2.5

start

Every month Check ECO---DRAIN for proper operation 9.2.2

Clean the surface of the condenser 9.2.3

If necessary Clean the ECO---DRAIN diaphragm valve 9.2.5

Every three month General checks 9.2.4

Every year Clean the ECO---DRAIN 9.2.5

The maintenance periods are recommended periods and may need to be adjusted based
on installation and service conditions.

9.2.1 Check the condensate outlet daily as follows:

Attention! If neither condensate nor compressed air exits, clean the

ECO -- DRAIN. (See chapter 9.2.5)

! Verify that condensate exits from the hose of the condensate drain outlet when the
drain opens (the LED extinguishes for a short period).

9 --- 24
 Maintenance

9.2.2 Check ECO -- DRAIN for proper operation monthly, as follows:

Check the function of the condensate drain by pressing the TEST pushbutton on the upper
housing of the ECO---DRAIN. The solenoid valve of the ECO---DRAIN opens when the TEST
pushbutton is pressed.

8 9
8 Operational status --- light emitting diode
9 TEST pushbutton (condensate drain)

! Press the TEST pushbutton on the ECO---DRAIN housing.

Press the test pushbutton for at least 1 second. The valve will open every 2 to 3 seconds.
The LED will flash to indicate the valve’s opening and closing. Note that all accumulated
condensate should drain.
Condensate does not drain:
" Outlet hose of the ECO---DRAIN is blocked.
If necessary, clean or replace the outlet drain hose.
" Diaphragm valve is clogged.
See chapter 9.2.5.
" Solenoid coil is defective.
Contact authorized KAESER distributor.

9.2.3 Cleaning the condenser

Clean the condenser every month.
! Stop the refrigerated dryer by turning the switch (1) to the “off” position.
! Lock the switch (1)with a suitable padlock to prevent unauthorized switch ---on.
! Clean the cooling fins of the refrigerant liquefier by blowing compressed air from the
outside to the inside.
See chapter 8.2 to start the refrigerated dryer.

9.2.4 General checks

! Inspect the electrical components of the refrigerated dryer every two to three months.
Correct any malfunctioning or worn components, such as loose connections or over-
heated cable immediately!

Escaping compressed air and/or refrigerant can cause injury to per-

sonnel and lead to damage to the dryer.

! Check all pipework, hoses and screwed fittings for leakage every two to three months
and carry out a visual check for any external damage. Correct any faults immediately!

9 --- 25
 Maintenance

The refrigerant contained in the refrigerating system may not be

vented to the open air. Always use a refrigerant recovery system when
working on the refrigerant circulation.
Dispose of unusable refrigerant according to environmental regula-
tions!

9.2.5 Cleaning the ECO -- DRAIN

Clean the condensate drain monthly, or more frequently depending on the degree of con-
tamination of the compressed air.
It is recommended that the ECO---DRAIN is cleaned after the first 50 hours of service.
Maintenance work on the ECO---DRAIN is only possible with the ECO---DRAIN removed.
Initial work:
! Stop the refrigerated dryer by turning the switch (1) to the “off” position.
! Lock the switch (1)with a suitable padlock to prevent unauthorized switch ---on.

Before removing up the ECO -- DRAIN it must be shut off from the com-
pressed air.

! Close the shut ---off valve in the air line to the ECO---DRAIN.

Shut ---off valve Shut ---off valve

closed opened

Removing the ECO -- DRAIN:

! Depressurize the ECO---DRAIN by pressing the TEST pushbutton.
! Unscrew the screw fittings between the shut ---off valve and the ECO---DRAIN.
! Take out the ECO---DRAIN.

Attention! The ECO -- DRAIN is still connected to the power supply cable.

9 --- 26
 Maintenance

11

10

9
8
7

6
5

1 2 3

1 Cross ---head screws, M5 x 2.5 7 O Ring, 28 x 1.5

2 Diaphragm 8 Thrust spring for valve piston
3 O Ring, 6 x 1.5 9 Valve piston
4 Diaphragm seat 10 Housing
5 Thrust spring for diaphragm 11 Top cover
6 Diaphragm cover

Items in ( ) refer to items detailed in the previous figures.

Removal of the ECO -- DRAIN:

Attention! Watch for loose parts fitted into each other that could easily be lost
when disassembling the ECO -- DRAIN.
Note the final positions of the individual parts.

! Unscrew the four cross---head screws (1) on the diaphragm seat (4) and remove care-
fully with the diaphragm cover (6) from the housing (10). Watch for loose parts, such
as the pressure springs (5) and (8), diaphragm (2) and the O rings (3) and (7)!

Cleaning:
! Remove the thrust spring (5), diaphragm (2) and valve piston (9) with its thrust spring
(8) and clean them.

Do not direct compressed air toward any person at any time.

Compressed air is contained energy and as such, is dangerous to life.

Wear protective goggles when blowing out components.

! Blow out the diaphragm seat (4), diaphragm cover (6), and the housing inside with
compressed air.

9 --- 27
 Maintenance

Reassembly of the ECO -- DRAIN:

Attention! It is recommended that parts subject to wear, such as the diaphragm,

valve piston and O rings are renewed for reasons of safety and relia-
bility.

! Check the diaphragm (2), the existence and correct seating of the O rings (3) and (7)
on the diaphragm seat (4) and diaphragm cover (6). Renew defective parts.
! Check the valve piston (9) for signs of wear and renew, if necessary.
! Check the existence and correct seating of the thrust spring (8) for the valve piston (9).
! Insert the valve piston (9) into the guide hole in the housing.
! Place the thrust spring (5) over the nipple on the diaphragm cover (6). Check that the
thrust spring (5) sits correctly.
! Fit and position the diaphragm cover (6) over the valve piston (9) in the housing.
! Fit the diaphragm (2) into the opening in the diaphragm seat (4).
! Fit the diaphragm seat (4) to the diaphragm cover (6). Check that the thrust spring (5)
is positioned in the recess provided in the diaphragm (2). Insert the four cross---head
screws (1) through the holes provided in the vertically assembled diaphragm seat, dia-
phragm cover and housing and screw the components together tightly.

Final work:
! Fit the ECO---DRAIN back into the refrigeration dryer with the screw fittings.
! Open the shut ---off valve (in the compressed air line to the ECO---DRAIN).
! Carry out a functional check of the ECO---DRAIN (see chapter 9.2.2).
See chapter 8.2 to start the refrigerated dryer.

9 --- 28
 Spare Parts and After Sales Service

10 Spare Parts and After Sales Service

Provide the following details for all queries and spare parts orders:
(see also the name plate)
Refrigerated dryer, model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part name: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part order number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Always provide the date of initial start up when making claims under warranty!

Name plate:

lb.

psig

psig

1ph
3ph

min. 40 F / max. 110 F

10 --- 29
 Appendix

11 Appendix

11.1 Wiring Diagram

11 --- 30
 Appendix

11.2 Maintenance Schedule

Refrigerated dryer, model:

Serial number:
Date Description of work Operating hours Signature

11 --- 38