KAESER KOMPRESSOREN SX, Service Manual

Page 1: ...Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 2: ...Original instructions KKW SSX 1 04 en SBA SCHRAUBEN SCB...

Page 3: ...pecified Use 12 3 3 Improper Use 12 3 4 User s Responsibilities 12 3 4 1 Observe statutory and universally accepted regulations 12 3 4 2 Qualified personnel 13 3 4 3 Adherence to inspection schedules...

Page 4: ...erved before before Every Start Up 36 7 3 Checking installation and operating conditions 37 7 4 Setting the overload protection cut out 38 7 5 Filling cooling oil into the airend 38 7 6 Checking direc...

Page 5: ...4 10 15 Changing the oil filter 66 10 16 Changing the oil separator cartridge 67 10 17 Document maintenance and service work 69 11 Spares Operating Materials Service 11 1 Note the Nameplate 70 11 2 Or...

Page 6: ...Contents iv Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 7: ...edging messages 44 Fig 16 Filter mat for the air and oil cooler 53 Fig 17 Control cabinet ventilation grill 54 Fig 18 Filter mat for the air and oil cooler 55 Fig 19 Air filter maintenance 56 Fig 20 C...

Page 8: ...List of Illustrations vi Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 9: ...4 Mains supply 380V 3 60Hz 11 Tab 25 Mains supply 440V 3 60Hz 11 Tab 26 Mains supply 460V 3 60Hz 11 Tab 27 Inspection intervals according to Ordinance on Industrial Safety and Health 14 Tab 28 Danger...

Page 10: ...List of Tables viii Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 11: ...tallation declaration Missing documents can be requested from KAESER Make sure all documents are complete and observe the instructions contained in them Make sure you provide the data from the namepla...

Page 12: ...to safety are named that will help you to avoid dangerous situations This bullet is is placed by lists of actions comprising one stage of a task In lists of actions with several stages the sequence o...

Page 13: ...aximum working pressure Ambient temperature Tab 2 Nameplate 2 2 Options The table contains a list of possible options Enter options here as a reference Option Option code Exists Modulating control C1...

Page 14: ...mbient conditions SX 3 SX 4 SX 6 SX 8 Maximum altitude AMSL m 1000 1000 1000 1000 Permissible ambient tem perature C 3 45 3 45 3 45 3 45 Cooling air temperature C 3 45 3 45 3 45 3 45 Inlet air tempera...

Page 15: ...st fan for forced ventilation Flow rate m3 h at 100 Pa 1000 1200 1500 2000 Tab 7 Ventilation 50Hz Mains frequency 60 Hz SX 3 SX 4 SX 6 SX 8 Inlet aperture Z see fig ure 8 m2 0 2 0 2 0 2 0 2 Extractor...

Page 16: ...e air delivery FAD m3 min at 50 Hz Maximum working pres sure bar SX 3 SX 4 SX 6 SX 8 8 0 34 0 45 0 60 0 80 11 0 26 0 36 0 48 0 67 15 0 25 0 36 0 53 Tab 11 FAD 50 Hz FAD m3 min at 60 Hz Maximum working...

Page 17: ...cosity at 40 C 45 mm2 s D 445 ASTM Test 44 mm2 s DIN 51562 1 50 7 70 0 mm2 s D 445 ASTM Test Viscosity at 100 C 7 2 mm2 s D 445 ASTM Test 6 8 mm2 s DIN 51562 1 8 2 710 4 mm2 s D 445 ASTM Test Flash po...

Page 18: ...6 SX 8 8 5 3490 3520 3520 3540 11 3490 3520 3520 3540 15 3520 3520 3540 Tab 17 Drive motor rated speed 60Hz 2 12 Sound pressure level Operational state Nominal volume flow Nominal pressure Measuremen...

Page 19: ...e machine may not be connected to a three phase supply in which one of the phases is earthed as this can lead to dangerous voltage surges Connection to an IT supply is not permitted without further me...

Page 20: ...y to private power supplies within industrial areas isolated from the public mains Machines with current consumption 16 A 75 A comply fully with IEC 61000 3 12 The machines listed in table are intende...

Page 21: ...t drawn A 6 7 9 12 Tab 24 Mains supply 380V 3 60Hz Rated power supply 440V 10 3 60Hz SX 3 SX 4 SX 6 SX 8 Mains fusing A 10 10 16 16 Supply cable mm2 4x1 5 4x1 5 4x2 5 4x2 5 Current drawn A 5 6 8 10 Ta...

Page 22: ...e manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated for such...

Page 23: ...ppropriate measures to safeguard persons and property have received adequate training and authorisation for the safe installation and maintenance on this equipment Additional qualifications for compre...

Page 24: ...e found here Electricity Allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out work on electrical equipment...

Page 25: ...enclosure while the machine is switched on Switch off and lock out the power supply disconnecting device and check that no voltage is present Wear close fitting clothes and a hair net if necessary Mak...

Page 26: ...rms to local safety regulations Allow transport only by personnel trained in the safe movement of goods Attach lifting gear only to suitable lifting points Be aware of the centre of gravity to avoid t...

Page 27: ...er these areas Activity Danger area Authorised personnel Transport Within a 3 m radius of the machine Installation personnel for transport preparation No personnel during transport Beneath the lifted...

Page 28: ...ne only with closed safety guards access doors and panels Switch off and lock out the power supply disconnecting device and check that no voltage is present before opening any machine enclosure or gua...

Page 29: ...tment Our general terms and condi tions of business apply with regard to warranty A condition of our warranty is that the machine is used for the purpose for which it is intended under the conditions...

Page 30: ...otection regulations Observe relevant national regulations This applies particularly to parts contaminated with cooling oil Do not allow cooling oil to escape to the environment or into the sewage sys...

Page 31: ...ooling air flow The enclosure is not suitable for the following uses Walking on standing or sitting on As resting place or storage of any kind of load Safe and reliable operation is only assured with...

Page 32: ...e oil then flows through the oil filter 4 and back to the point of injection Pressure within the machine keeps the oil circulating A separate pump is not necessary A thermostatic valve maintains optim...

Page 33: ...d LOAD Contact open IDLE When the contact closes the machine switches to LOAD When the contact opens the machine switches to IDLE At the end of the idling period the machine switches to STANDSTILL and...

Page 34: ...falls with the air demand The regulating valve is factory set The setting should not be changed without consultation with KAESER Service 4 6 2 Control modes Using the selected control mode the contro...

Page 35: ...air delivery is continuously varied within the control range of the machine This control mode is not available on variable speed machines with a frequency controlled drive SFC Compressed Air Demand Op...

Page 36: ...rameter list Reduces a parameter value 7 UP Scrolls up the parameter list Increases a parameter value 8 escape Exits the edit mode without saving 9 enter Enters edit mode Exits the edit mode and saves...

Page 37: ...ning 1 xx x Current system pressure in bar psi or MPa 2 yy Current airend discharge temperature ADT in C or F 3 z Display of parameters and their settings see table 35 4 1 2 Error code for alarm and w...

Page 38: ...displayed in either C or F 5 Units used for display of pressure The current working pressure can be displayed in bar psi or MPa 6 Control modes Factory setting OFF This parameter changes the control...

Page 39: ...rs F Options The displayed value informs KAESER Service concerning the controller s internal ma chine configuration Tab 35 Parameter Further information Means of changing or adjusting parameters are g...

Page 40: ...ts explosive or chemically unstable gases or vapours acid alkaline forming substances particularly ammonia chlorine or hydrogen sulphide Ensure sufficient and suitable lighting such that the display c...

Page 41: ...ilation is insufficient a partial vacuum can be created in the room 1 Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine an...

Page 42: ...Further information on installation of exhaust air ducts can be found in chapter 13 3 5 3 Operating the Machine in an Air System If the machine is supplying an air system the system operating pressur...

Page 43: ...ressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 Check all hose couplings in the compressed air system with...

Page 44: ...electricity supplier 3 Test the overload protection cut out to ensure that the time it takes to disconnect in response to a fault is within the permitted limit 4 Select supply cable conductor cross se...

Page 45: ...s 3 Use a screwdriver to open the spring loaded terminals and insert the ends of the conductors in the square openings above the corresponding terminals 4 Secure the cable so there is no tension on th...

Page 46: ...Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers co...

Page 47: ...supply disconnecting device installed 6 4 Does the power supply conform to the specifications on the name plate 2 1 Are the power supply cable conductor cross sections and fuse ratings adequate 2 14 D...

Page 48: ...e fluctuations temperature influences or component tolerances the setting can be higher than the arithmetical phase current Check the overload protection cut out setting The overload protection cut ou...

Page 49: ...se sequence meter Switch the machine on and off again the moment the drive motor begins to turn Compare the direction of rotation of the motor with the arrows on the motor and the airend casing If the...

Page 50: ...e at least once a week during the first 4 weeks of operation Condensate in the cooling oil Contact KAESER Service Further information Information on draining off cooling oil is given in chapter 10 14...

Page 51: ...rease buffer capacity Setpoint pressure switching point 1 Scroll with the arrow keys until the parameter D setpoint pressure switch point is displayed in line 3 2 Press and hold enter for at least 3 s...

Page 52: ...ntroller has carried out a self test the green controller ON LED lights continuously 2 Press the ON key The green Machine ON LED lights continuously If a power failure occurs the machine is not preven...

Page 53: ...extinguishes 8 2 Switching Off in an Emergency and Switching On again The EMERGENCY STOP pushbutton is located below the control panel Fig 14 Switching off in an emergency 9 EMERGENCY STOP pushbutton...

Page 54: ...ectify the fault and acknowledge the message with the acknowledge key alarm LED extinguishes The machine is now ready to start again Warning message Message coming LED flashes Message gone LED extingu...

Page 55: ...not password protected Precondition The current parameter setting flashes Use the UP DOWN keys to change the value of the parameter and confirm with enter Changing a password protected parameter Some...

Page 56: ...nterlocked access door open or panel removed Unlatch the EMERGENCY STOP pushbutton Close the access door or fit the panel 2 Motor alarm Overload protection of drive or fan mo tor if fitted Frequency c...

Page 57: ...r housing exceeded Ensure adequate ventilation Ensure that the permissible room temperature is not exceeded 8 Spare Tab 39 Alarm indications 9 3 Warning messages he error code appears in the 4th line...

Page 58: ...IDLE more than twice per minute Air receiver too small Increase size of air receiver Airflow into the compressed air network restricted Increase air pipe diameters Check filter elements The different...

Page 59: ...is no voltage on floating relay contacts Working on pressure systems 1 Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow...

Page 60: ...counter counts down the operating hours to the next maintenance task The counter reading shows the number of operating hours to the next periodic machine maintenance Reset the counter to the original...

Page 61: ...2 4 Cooling Oil Change Interval Duty cycles and ambient conditions are important criteria for the number and length of the change intervals KAESER Service will support you in determining suitable inte...

Page 62: ...sks carried out punctually taking ambient and operating conditions into account Interval Service task Up to 12 000 h Have the valves checked Up to 12 000 h at the lat est every 3 years Check the drive...

Page 63: ...acing the Control Cabinet Filter Mats Filter mats protect the control cabinet from ingress of dirt If the filter mats are clogged adequate cooling of the components is no longer ensured In such a case...

Page 64: ...l 10 5 Cooler Maintenance Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air The frequency is mainly dependent on local operating conditions A leaking cooler...

Page 65: ...ER service representa tive Checking the cooler for leaks Visual check Is cooling oil evident Is a cooler leaking Have the defective cooler repaired immediately by an authorized KAESER service repre se...

Page 66: ...ive belts Material Spare parts if required Precondition The supply disconnecting device is switched off the device is locked off a check has been made that no voltage is present The machine has cooled...

Page 67: ...ioning nut 3 until the markings 4 coincide 8 Tighten one fixing screw 1 to hold the motor in place then tighten the rest 1 and 2 Result The drive belts are sufficiently tensioned It is not necessary t...

Page 68: ...15 bar should be tested only by KAESER Service Blow off protection and air system pressure monitoring are switched off during the test The machine must be isolated from the compressed air network and...

Page 69: ...off or working pressure rises to 10 above the activating pressure of the pressure relief valve 4 If necessary vent the machine and replace the defective pressure relief valve Returning the machine to...

Page 70: ...ine 1 Hose coupling air cooler venting 2 Pressure gauge 3 Hose coupling oil separator tank venting 6 Male hose coupling 7 Shut off valve A Shut off valve open B Shut off valve closed 8 Maintenance hos...

Page 71: ...on from the shut off valve to the minimum pressure check valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pr...

Page 72: ...ally as soon as the machine is stopped Venting takes place in three stages Isolate the compressor from the air system Vent the oil separator tank Manually vent the air cooler WARNING Compressed air Co...

Page 73: ...valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pressure 3 Disconnect the male hose fitting 6 and close the...

Page 74: ...fter a long period of standstill Material Cooling oil Cooling oil receptacle The maintenance hose with hose coupling and shut off valve is stowed beneath the oil separator tank WARNING There is risk o...

Page 75: ...nance hose to the exter nal air supply 4 Open the shut off valve 7 until the pressure gauge on the oil separator tank reads 3 5 bar 5 Close the shut off valve 7 and remove the male hose fitting from t...

Page 76: ...tween the machine and the compressed air network 3 Switch on the power supply and reset the maintenance interval counter 4 Start the machine and check the oil level again after about 10 minutes toppin...

Page 77: ...r supply and reset the maintenance interval counter 4 After about 10 minutes check the oil level again and top up if necessary 5 Switch off the machine and check visually for leaks 10 16 Changing the...

Page 78: ...ator cartridge anticlockwise and wipe off any drops of oil 2 Lightly oil the new filter s gasket 3 Turn the oil filter clockwise by hand to tighten Dispose of parts and materials contaminated with oil...

Page 79: ...tenance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 46 Logged maintenance tasks 10 Maintenance 10 17 Document maintenance and service work...

Page 80: ...al injury may result Use only genuine KAESER spares and operating materials Have an authorized KAESER Service Technician carry out regular maintenance Machine Name Quantity Number Air filter element 1...

Page 81: ...the help of this parts list you can plan your material requirement according to operating conditions and order the spare parts you need Make sure that any service or repair tasks not described in thi...

Page 82: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 72 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 83: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 73...

Page 84: ...ed no pressure 1 Allow the machine to cool down completely 2 Disconnect all air and electrical connections 12 2 Packing A wooden crate is required for overland transport to protect the machine from me...

Page 85: ...he forks are fully under the machine Fig 28 Transporting with a forklift truck Drive the forks completely under the machine or palette and lift carefully 12 4 3 Transporting with a crane Suitable lift...

Page 86: ...tion The machine is decommissioned 1 Completely drain the cooling oil from the machine 2 Remove used filters and the oil separator cartridge 3 Hand the machine over to an authorized disposal expert Co...

Page 87: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 77...

Page 88: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 78 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

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Page 91: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 81...

Page 92: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 82 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 93: ...e and Instrument Flow Diagram P I diagram MODULATING control mode 13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGM...

Page 94: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 84 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 95: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 85...

Page 96: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 86 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 97: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 87...

Page 98: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 88 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 99: ...13 3 Dimensional Drawing 13 Annex 13 3 Dimensional Drawing 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 89...

Page 100: ...13 Annex 13 3 Dimensional Drawing 90 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Page 101: ...13 Annex 13 3 Dimensional Drawing 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 91...

Page 102: ...13 4 Electrical Diagram 13 Annex 13 4 Electrical Diagram 92 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

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